Question 1

What are the most common causes of hydraulic system failure?

Accepted Answer

There are many reasons that could cause a hydraulic system to break down, many of which are preventable if carefully monitored. Here we take a look at some of the signs and symptoms of hydraulic failure.

Fluid contamination

One of the main reasons hydraulic systems fail is due to fluid contamination. Whatever the type of fluid being used, if it becomes contaminated with any dust, dirt, or moisture, this can reduce the pumps ability to control system pressures. This in turn, can lead to overheating or a build-up in the system that causes the parts to seize and fail.

Always ensure that the different components and fluids are clean and fit for purpose before use, to prevent failure from occurring.

Poor or irregular maintenance

Servicing is vital to keep a system running smoothly. It is important to ensure that the system’s oil and filters are changed appropriately. Poor or irregular maintenance could cause the system to become contaminated, increasing wear on the pump and associated equipment.

The suction hose between the tank and pump also needs to be in good condition and replaced if any sign of wear.

It is good practice to inspect a hydraulic unit regularly, checking the oil levels, cleaning up any spillages and reporting any defects immediately.

Misuse and human error

It is imperative that proper instruction and training is given to anyone that is using an application operated by a hydraulic system. Faulty installation, using incompatible parts or improper usage are all major factors that can cause failure.

Environmental & operating factors

Temperature and working conditions all have an impact on the system.

The power unit needs be housed or operated in a well-ventilated area, so that the oil coolers are kept free from dust and contamination.

Is the application operating in high temperatures? If so, close attention will need to be given to the type of fluid used and specialist seals will need to be installed, in all applications. Always avoid using mineral based oils in high temperature applications, these are refined from crude oil and have a flash point, which means that they will ignite at a certain temperature.

If the application is operating in cold environments, a tank heater may need to be installed, in order to maintain the fluid viscosity. Hydraulic fluid that is too thick or too thin can cause damage to the system.

Aggressive working conditions can also put strain on a system, leaving it vulnerable to failure. External shocks and vibration can cause surging and cavitation between the tank and the inlet of the pump. This can be avoided by properly mounting the power unit on special anti-vibration units.

The hydraulic tank also needs to be mounted higher than the pump and kept as close together as possible.

No matter what the application, hydraulic system failure is inevitable at some point. However, issues can be avoided if you ensure that you regularly follow all maintenance procedures and make certain that the appropriate components are installed or replaced correctly. If you are unsure of anything, don’t be afraid to call on your industry peers or hydraulic professionals for their help and advice.

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Question 2

how does a hydraulic cylinder work

Accepted Answer

Seals are essential to fluid power engineering, as they prevent a fluid or gas from passing between the different components of a hydraulic cylinder.

Dynamic (used when parts are in motion) or static (fixed application), different types of seals, each have their own role to play, in ensuring a cylinder runs as smoothly as possible.

Our quick guide below shows the main types of seals that you would find in a cylinder and describes how they operate.

Wiper Seals

Wiper seals or Scraper seals are designed in a way to keep external contaminants out of a hydraulic system, by cleaning the rod in the cylinder on each cycle.

Rod Seals

Also known as Gland seals, Headbush or Neck Seals, Rod seals act as a pressure barrier to maintain and regulate the operating fluid in a cylinder. They can seal the pressure from one side (single-acting) or from both sides (double-acting). Rod seals are key in preventing corrosion.

Static Seals

These are used to create a seal between fixed components. The full range of static seals include o-rings, back-up rings, flange seals, bonded washers and OP seals.

Piston Seals

Piston seals are important for controlling the motion of a cylinder. It creates a barrier for dynamic pressure between the piston and the cylinder, preventing fluid from passing the piston and allowing the cylinder to extend and retract.

Guide Rings

Guide rings also known as bearing rings, stop metal-to-metal contact between two dynamic cylinder components. This is crucial in the prevention of damage to the two moving surfaces.

The right seal for the job

When selecting the best seals for your hydraulic ram, both at OEM or repair stage, it’s important to consider the parameters of the application and the operating conditions.

High pressure, medium used, extreme temperatures, aggressive chemicals, working environment and legislation standards will all have an impact on the chosen material of seal.

Over time however, it is expected that hydraulic seals will eventually need replacing, this can be down to general wear and tear, improper installation or exposure to extreme elements.

Most replacement seals, for most applications can be found off the shelf and seal kits for well known applications can be picked up easily.

If you require any further advice regarding seals and their applications, the team of experts at FPE Seals can help you source what you need.

Can’t find what you’re looking for? We can also custom-manufacture a full range of seals, in a full range of materials to meet your exact requirements.

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Question 3

What is a Hydraulic Ram and How Does It Work?

Accepted Answer

A hydraulic ram is a cylinder with a movable rod that can move a mass, or an obstruction as so required.

In principle, a hydraulic cylinder ram works by an external fluid being pumped into either side of a cylinder simultaneously, this creates a high pressure and low-pressure side within the cylinder depending on the load that it is trying to move.

Here we explore some of your commonly asked questions surrounding hydraulic rams, what they’re used for, how hydraulic devices work, and how hydraulic rams work.

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How does a hydraulic device work?

Hydraulic devices use fluid that is moved by an external pump driven by a power unit. Hydraulic devices are designed around the principle that liquids are always considered to be incompressible. This means that when a force is applied at one point, the liquid will transfer an equal force at another point.

Most common hydraulic devices work by using a hydraulic pump, a reservoir for fluid storge to the pump. Mechanical energy is converted to hydraulic energy, moving the liquid through a system. Valves are used to regulate the flow of the liquid and control the pressure of the device. A hydraulic cylinder then converts the hydraulic energy back into mechanical energy.

There are a variety of hydraulic devices, including hydraulic rams, but most will use these components in their operation.

How do hydraulic rams work?

Hydraulic rams consist of several components:

• Cylinder
• Piston
• Neck Gland
• Rod
• Cylinder Ports
• End Caps

The area between the piston and the gland (rod side) is called the Annular side, & the area between the piston & the end cap is called the Full-Bore side.

Pumping fluid into the cylinder port on the Annular side of the cylinder will result in the rod being retracted, giving you a closed centre. Reverse the flow into the opposite port on the Full-Bore side and the piston will then extend the rod out of the cylinder (open centres), at the same time pushing the oil from the Annular side (low pressure) back to tank.

What is a hydraulic ram used for?

Today, hydraulic rams are used all over and have a variety of uses, from heavy plant and mining machinery such as excavators and diggers, agricultural equipment, to food & beverage and packaging machinery, deep sea, marine and automotive applications, to hand tools, fairground amusements and even zoo doors...the list goes on and on.

FPE Seals is a manufacturer and distributor of hydraulic cylinder parts and seal kits for devices including hydraulic rams. Shop online or contact us and find out how our cylinder parts can help improve your hydraulic systems.

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Question 4

Seal Failure: Common Causes and Cures

Accepted Answer

In the world of machinery, repair and maintenance is a simple fact of life. So, it should come as no surprise that when it comes to sealing products being used for hydraulic and pneumatic applications, wear and tear is inevitable

Even when you have diligently installed the most robust product, in the best kind of material, certain factors will always lead to seals eventually having to be replaced.

Thankfully in most cases, problems can be identified early, before any serious operational damage can occur, and seals are easily reinstated.

Here we take a look at typical seal failure, the likely causes, and what can be done to rectify the problem.

Hardening

Hardening of the dynamic face has caused glazing and cracks.

Cause: Heat generated by high speed.

Cure: Slow stoke speed or use an alternative seal device.

The whole seal has gone hard and elasticity is lost.

Cause: High fluid temperature, deterioration of fluid or problem with the compatibility of the seal to the fluid.

Cure: Lower the oil temperature, renew fluid or change to a different seal compound.

Wear

The dynamic face of the seal is worn to a glossy mirror-like finish.

Cause: Insufficient lubrication

Cure: Check oil viscosity or use an alternative seal device.

Wear on dynamic lip of seal is egg-shaped.

Cause: Rod or piston bore is not concentric

Cure: Hone to within seal specifications or replace the worn rod or cylinder tube.

Signs of abnormal wear on one side of the dynamic lip.

Cause: Worn bearing or wear ring. Excessive lateral load.

Cure: Replace bearings. Increase bearing area.

Scarring

Cut or dent on the lip.

Cause: Storage on a nail or peg. Improper installation tool

Cure: Store flat in a plastic bag in a closed cardboard box. Installation tools should not have sharp edges.

Scratched on the dynamic side.

Cause: Scars on the rod or bore or foreign material in fluid

Cure: Hone, polish and deburr metal parts or flush the system.

Swelling

Material is soft and misshaped.

Cause: Absorption of fluid. Fluid and seal are incompatible or the there is water in the system.

Cure: Change the seal compound or system fluid. Or flush the system.

Deterioration

Cracks and loss of elasticity. The material easily crumbles.

Cause: High fluid temperature. Exposure to ozone or sunlight.

Cure: Lower oil temperature. Store seals away from sunlight and arc welding area.

Grooving

Axial cuts on the dynamic side.

Cause: Metal chips or other foreign material in system. Imploding air bubbles.

Cure: Flush System. Bleed air from the system.

Extrusion

Extruded material on the dynamic side of heel

Cause: Gap between mating surfaces is too wide, worn bearings or extreme pressure.

Cure: Employ a back ring, replace the bearings or use an alternative seal.

Extruded material on the static side of the seal.

Cause: Uneven support surface or undersized back-up ring.

Cure: Machine surface. Correct back up size.

Fracturing

Chunks of material torn from the dynamic side.

Cause: Excessive back pressure.

Cure: Check relief valves.

Pressure side of seal burned and broken.

Cause: Explosion of residual air at high pressure. ‘Dieseling’

Cure: Bleed air from the system.

Long cracks in the “V” portion of the seal.

Cause: Frequent high pressure shocks or spikes. Low temperature start-up.

Cure: Use alternative style seal. Warm system before applying pressure.

Breaking off of entire dynamic side.

Cause: Deterioration of material and/or fluid.

Cure: Use alternative material or seal. Flush system.

Replacement seals and seals kits, for most applications can be found off the shelf and despatched to you quickly.

If you require any further advice regarding seals and their application, the team of experts at FPE Seals can help you source what you need.

Can’t find what you’re looking for? We can also custom-manufacture a full range of seals, in a full range of materials to meet your exact requirements.

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Question 5

Trouble Shooting Common Cylinder Creep

Accepted Answer

Cylinder drift is a common problem that can occur with hydraulic systems of all types.

Tim Bone, FPE Seals Cylinder Parts Manager

This is something that FPE Seals Cylinder Parts Manager Tim Bone knows only too well and is often offering our customer advice on how to troubleshoot the problem. Here he explains more on how you can get to the root cause of your creeping cylinder.

What is causing a hydraulic cylinder to creep faster than expected?

Often the cylinder on a hydraulic application can creep. The popular assumption for this, is that the problem is due to oil passing over a worn piston seal.

However, Tim explains, “Often customers tell me that even when they have resealed the cylinder several times, it still weeps down.

“In many cases, the more likely cause is that the oil is passing across the spoil, rather than the problem being with the seals.

“A simple way to test this, is to lower the load onto the ground so that the cylinder is not under tension, isolate the power source i.e. the hydraulic unit and relax the pressure in the system.

“You can then remove the hose, from the cylinder port that the direction of the rod is moving in (i.e. if the rod is extending, then remove the hose from the annular side, if the rod is retracting then remove it from the bore side). Place a high-pressure ball valve in the line, attaching the hose to the opposite side of the ball valve.

“Make sure that all connecting joints are tight and leak-proof and clean up any spillages.

“Move the lever of the ball valve to open position. Restart the hydraulic power source and operate the valve block (levers), placing load onto the cylinder concerned.

“If the cylinder shows signs of dropping again, move the lever of the ball valve to the closed position.

“If the cylinder stops creeping, this proves that the fault is in the main valve block, as generally the only seals in a valve block are the ones at each end of the spool, to stop oil from leaking externally.

“Hydraulic spools in valve blocks are a machined precision fit, over time the spools can wear across the surfaces causing oil to pass between the internal galleries. Fitting a standard pilot operated check valve or over centre valve can stop this from happening.

“If the cylinder continues to creep, then the problem is with the internal seals of the cylinder. Once identified these seals can be easily replaced.”

Replacement seals for most applications can be picked up off the shelf. FPE Seals stock and supply a full range of seals, including piston seals for all engineered applications.

If you require any further advice regarding seals and their application, the team of experts at FPE Seals can help you source what you need.

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Question 6

What are hydraulic seals made of?

Accepted Answer

Hydraulic seals are non-metallic rings used in fluid power engineering, that prevent a fluid or gas from passing between different components of a cylinder, used in industrial applications.

Just as seals come in all shapes and sizes, for a multitude of applications, they also come in a variety of materials.

Most hydraulic seals use polymeric materials such a polyurethane, elastomers, rubber or polytetrafluroroethylene (PTFE).

The selected material of the seal will depend on the end use. Operating conditions such as high pressure, fluid compatibility, extreme temperatures, aggressive chemicals, working environment and legislation standards all impact on the chosen material.

Below are just some examples of common polymeric materials used to fabricate seals, utilised due to their hardwearing properties:

Polyurethane
Blue polyurethane (Food and Drug Association (FDA) compliant)
Nitrile
Viton/FKM
Silicone
Polyacetal (POM)
PTFE (in its virgin state or can be filled with either glass, bronze or carbon)
Ultra-high-molecular-weight polyethylene (UHMWPE)
Nylon
Polyether ether ketone (PEEK)
Polyester
Tufnol/Phenolic
AFLAS
NORSOK MATL (Oil & Gas industry compliant)

When choosing the right type of seal, to ensure the safe and optimum performance of a machine, seal material plays a big factor.

Not sure what you need? Get in touch with our knowledgeable team here at FPE Seals, who will discuss your requirements based on your application, and help you find the right seal for the job.

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Question 7

Why is it important to bleed the air from a hydraulic system?

Accepted Answer

Air that enters a hydraulic system can cause many problems that could subsequently lead to system failure. Here we discuss how you can spot and prevent these potential problems and why it is so important that air is bled from a system as soon as it is detected.

Hydraulic pumps are not designed to pump air, essentially because when compressed, air generates heat. When air contaminates a hydraulic fluid, usually via the pump’s inlet, aeration, cavitation, or foaming can occur.

Aeration is bad news, as it degrades the hydraulic fluid causing damage to the components of the system due to loss of lubrication, resulting in overheating and burning of the seals. Overheating is particularly dangerous as dieseling can occur when the hydraulic cylinder oil mixes with the air, causing an explosion under compression.

Cavitation, brought on by the rapid changes of pressure in the fluid, causes small vapour-filled bubbles to contaminate the system, which implode when compressed. Ultimately this leads to metal erosion, which harms the system’s components and contaminates the fluid.

Air can also cause foaming in the tank, causing the equipment to operate erratically, as the pump takes large gulps of air along with the oil.

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When to bleed a hydraulic system

Abnormal noise is often a tell-tale sign that there is trapped air in a hydraulic system. As air circulates through the system it compresses and decompresses, creating a banging or knocking noise.

This is why abnormal noise must always be checked out and careful inspection given to the condition of the system’s fluid, components and seals, to identify any signs of trapped air or contamination.

It is also important that displacement hydraulic cylinders are bled before installation, as any air trapped in the system would work like a gas shock absorber. For this reason, displacement cylinders have a breather at the top, to disperse any air.

And lastly, when testing a new hydraulic cylinder, it is important to check for potential air contamination, as this can result in blowing the dirt wiper and the hydraulic seal out of its housing extruding past the rod.

All things considered, if spotted early and dealt with quickly, bleeding trapped air in a system, will prevent any long-term damage or operational downtime.

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Question 8

How Are Hydraulic Seals Made?

Accepted Answer

Hydraulic and Pneumatic Seals for engineered machinery can be designed and manufactured in a variety of materials, shapes and sizes.

Selecting the right material

Most hydraulic seals are made from polymeric materials, more commonly polyurethane, polytetrafluoroethylene (PTFE), elastomers and rubber. Although, other materials can be used for more specialist seals.

It's important to select a material that best suits a seal's end use. For instance, the seal's operating conditions such as pressure, fluid compatibility, extreme temperatures, working environment and legislation standards, will all have an impact when deciding on which material to use.

Manufacturing process

During the manufacturing process, a Computerised Numerical Control (CNC) lathe machine is used to create the seal. These can be programmed with standard and customised seal profiles. Taking the digitalised data of the profile, the CNC lathe then works to cut the shapes of the seal from the selected material.

Take a look at our short video to see how seals are manufactured at FPE Seals.

Question 9

What is a Rod Seal?

Accepted Answer

Rod Seals, also known as Gland Seals, Headbush or Neck Seals are an integral part of any hydraulic or pneumatic cylinder system. Essentially, they are designed to seal between a cylinder’s rod and gland.

The Rod Seal acts as a pressure barrier to maintain and regulate the operating fluid when a cylinder is in dynamic motion, and so plays a key role in preventing leakage and corrosion.

They do this by sealing the pressure from one side (single-acting) or from both sides (double-acting) and work together with a Wiper Seal to protect the system from external contaminants.

For more heavy duty applications, a Buffer Seal can be used alongside a Rod Seal to provide even further resilience.

Rod Seals come in a variety of sizes, styles and materials, to meet the parameters of the cylinder’s application and operating conditions.

High pressure, extreme temperatures, fluid compatibility, working environment and legislation standards will all have an impact on the chosen material of seal.

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The range of Rod Seals include;

Grooved Rod Seals – A single-acting seal with an anti-extrusion ring on the internal diameter.

Rod Composite Seals – Energised by an o-ring, to provide low friction, non-stick/non-slip hard-wearing sealing.

Rotary Rod Seals – Used to seal a rotating shaft.

Rubber & Fabric Seals – When this type of material best suits the application.

T-Seals – T-shaped seal with two back up rings to help prevent extrusion.

Vee-Packing (Chevron) Seals – Multiple-lipped seals packed together in groups of three or five, used in medium to heavy duty applications.

If you require any further advice regarding Rod Seals and their applications, then our knowledgeable team at FPE Seals would be happy to help.

We stock, source and supply a fully range of Rod Seals. Can’t find what you’re looking for? We can also manufacture the seals to your specification, in a full range of materials to meet your exact requirements.

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Question 10

What Causes Hydraulics to Run Slow?

Accepted Answer

When it comes to a hydraulic system, a common complaint can be that it is operating slowly or less effectively than before. There are many reasons why this can occur, but this is mainly down to an issue with fluid flow and faulty or failing parts. Here we discuss the critical role that individual components play in hydraulics and why it may be that these components are causing the system to slow down.

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Hydraulic Tank/Reservoir – to avoid any issues a good tank or reservoir should always come fitted with a filler breather, suction strainer, site glass, removeable inspection/service plate and drain plug.

Suction Strainer – this is designed to remove any foreign bodies that may have contaminated the tank. Filters must be checked and cleaned on a regular basis. If they become blocked, they will restrict the flow of the hydraulic fluid entering the inlet side of the pump, causing the system to slow down and ultimately causing damage to the pump.

Filler Breather – this should also be checked regularly, to make sure that the cage is intact and free from foreign bodies. Check the breather cap and if required, clean using an appropriate solvent, to avoid the breather element from becoming clogged. If blocked, this can cause the tank to vacuum, which will lead to a restricted flow of oil to the pump.

Suction Hose – a short piece of hose is fitted between the outlet of the tank and the inlet of the pump. Over time, the rubber hose can degrade, becoming porous, and even delaminate internally, causing a restriction of fluid flow into the pump.

Hydraulic Pump – modern day pumps are extremely complex pieces of engineering and usually will not tolerate any form of contamination. Any foreign bodies in a pump can cause severe damage to its integral moving parts, resulting in low pressure and restricted flow. Any problems can be identified with a good quality flow meter.

Power Unit – one component that definitely needs to be checked for any problems is the power unit that is driving the hydraulic pump. This can be an electric motor or either a combustion engine. These can be checked by loading the pump with a flow meter. The tone of the power source should alter slightly under load but not die. If the flow drops and the power source stays the same, it may be worth checking the drive coupling between the output shaft and the input shaft of the unit.

System Relief Valves – these are prone to overheating and will change colour when the incorrect pressure rating is too high. This can cause damage to the seating face in the cartridge, causing oil flow to pass over the seat of the relief valve and return back to the tank via the tank line. A faulty or dirty relief valve can also have the same effect if set to low, the valve will run continuously open, losing flow and causing heat.

Directional/Proportional Control Valves – these can be fitted with additional or external valves that can be easily altered or damaged causing them to pass oil across and dumping it back to the tank. Always remember, any fluid will always take the easiest route away from the tank. The smallest imperfection on a seat, that cannot be felt but can be seen, will allow oil to pass.

Hydraulic Cylinder – just because there are no external signs of leakage does not mean to say that the internal piston seals of the cylinder are not worn or damaged. Although, usually there are identifying signs that the piston seals are worn. For instance, the cylinder may be dropping or have no lifting force.

In general, if your hydraulic system is running slowly when the fluid warms up, then this is due to the oil thinning and therefore able to pass easily across worn or damaged surfaces. Carrying out a simple flow test with a flow meter will help eliminate any of the key factors mentioned above.

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Question 11

What is a Wiper Seal?

Accepted Answer

Wiper Seals, also known as Scraper Seals or Dust Seals are primarily designed to prevent contaminants from getting into a hydraulic system.

This is usually achieved by the seal having a wiping lip that essentially cleans away any dust, dirt or moisture from the rod of a cylinder on each cycle. This type of sealing is crucial, as contaminants can potentially cause damage to the other components of the hydraulic system, and cause the system to fail.

The wiping lip always has a smaller diameter than the rod it is sealing. This provides a tight fit around the rod, to prevent any dirt getting in, when in both a static and dynamic position, while still permitting a reciprocating ram rod to pass through the inner bore of the seal.

Wiper Seals come in range of different styles, size and materials, to best suit the application and operating conditions of a fluid power system.

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Some Wiper Seals have secondary functions, this may include having a harder scraping lip to remove stubborn contaminants such as bonded dirt, frost or ice, or a secondary lip used to capture any oil that may have bypassed the main seal. These are commonly known as Double Lipped Wiper Seals.

In the case of a Flexible Wiper Seal, the seal is usually held in by its shoulder.

A Metal Cased Wiper Seal relies on the outer metal case having an interference fit to hold it in the housing. It will therefore measure slightly larger on the outside diameter.

If you require any further guidance on Wiper Seals, then our knowledgeable team at FPE Seals would be happy to help.

We stock and supply a fully range of Wiper Seals. If you can’t find what you’re looking for, we can also manufacture the seals to your specification, in a full range of materials to meet your exact requirements.

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Question 12

Why Are Hydraulic Cylinders Cushioned?

Accepted Answer

Cushioning, or soft start as it is sometimes referred to, is used to slow down a hydraulic cylinder, by reducing the speed of a piston at the end of its stroke, or before it meets the end cap. This method is generally used in double-acting cylinders, for heavy duty applications that use a lot of kinetic energy.

Cushioning is commonly fitted to both the rod side and full-bore side of a cylinder, to bring the final movement of the rod to a stop. This prevents the piston from slapping against the back of the gland and the end cap of the cylinder when opening and closing.

The ultimate purpose of using a cushioning method is to avoid damage to the piston, which could occur when a high oil volume is applied to a hydraulic cylinder.

Other advantages of using a cushioning method are that it extends the life of the cylinder by reducing the impact of vibrations, as well as reduces any excessive audible noises.

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How does hydraulic cylinder cushioning work?

Hydraulic cylinders operate by pumping a medium into the cylinder causing the piston to extend or retract to the end of its stroke.

A cushioning device works on the principle of forcing a small amount of the cylinder fluid through or over a smaller diameter / orifice which is usually present to the front or rear of the piston, as it comes to the end of its travel.

The cushioning device therefore restricts the flow of fluid to the back of the neck gland or base of the cylinder, which ultimately slows down the stroke of the cylinder as the fluid cannot go anywhere else, apart from through the tolerance aperture of the gland, resulting in slowing down the stroke to a stationary finish.

It is always best to decide whether to fit a cushioning device at the initial design and build stage of cylinder, as retro fitting can be a very costly.

Should you want any further advice on cylinder design and cushioning components, please contact our knowledgeable and helpful team today.

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Question 13

Why Do Hydraulic Cylinders Fail?

Accepted Answer

Hydraulic cylinders come in all shapes and sizes and are used in a variety of applications. The reasons why a cylinder can fail will depend on their application but in general, most problems are usually down to either physical damage or seal deterioration.

Suppose a cylinder is misused or has been physical damaged in some way. In that case, it can become a pressure intensifier, which causes harm to the different components, from misalignment, to the piston being pulled from the rod, to the drastic results of the cylinder splitting its full length.

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All cylinders are pressure-rated based on their application. Most are designed to work at 250bar, which normally applies to the extrusion tolerance of the seals used in the cylinder’s different components.

Seals will wear slowly over time, this cannot be prevented but is easily solved by spotting any problems early and replacing the worn seals, without causing any major issues to the hydraulic system.

However, excessive pressure, heat, misuse, and poor fluid condition will cause seals to deteriorate rapidly. For example, the seals can harden, crack, or extrude.

How to prevent cylinder failure

Areas to typically look out for cylinder failure is between the rod and the gland, the gland itself, the cylinder and around the welded parts.

All cylinders should be checked externally on a regular basis. Especially at the mounting points, steel pipes and hydraulic hose fitting. Anything that is loose should be rectified immediately. Make sure that there is sufficient lubrication and look out for any areas of excessive wear. Worn areas should be addressed without delay.

Particularly, check all external mechanical stops, as any damage can result in the piston or gland being pulled from its threads.

Inspect the condition of the chromed rod that moves back and forth in the cylinder. Any external dents, rust, scrapes or bends could lead to severe damage to the other integral components of the cylinder.

Always check the fluid levels of your hydraulic system, change the filter regularly and keep fluids free from contamination. This will prevent seal failure and damage to the cylinder bore.

Overall, cylinder failure can easily be prevented with careful use, regular inspection, and servicing, ultimately reducing the need for costly repairs and downtime.

If you would like any advice on sourcing replacement metal parts or seals for your hydraulic ram, please contact our helpful and knowledgeable team today.

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Question 14

What is a Piston Seal?

Accepted Answer

Piston Seals essentially provide a seal between a piston and cylinder bore.

The seal prevents leakage of hydraulic fluid or air, sealing dynamic pressure from one or both sides of a ram, to allow the cylinder to extend and retract.

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Piston Seals are dynamic by nature and come in a range of different styles, sizes, and materials. The type of seal needed will be dependent on the design of the cylinder, the application, the medium used, and its operating conditions.

Single-acting Piston Seals contain the pressure and prevent leakage on one side of the piston only. Therefore, the seal moves the piston along the cylinder in a single action.

Double-acting Piston Seals contain the pressure and prevent leakage from both sides of the piston. This drives the hydraulic or pneumatic ram both in and out, or stops it in a controlled position. Typically, double-acting seals have a symmetrical profile, with identical sealing functions on both sides.

Back up rings and guide rings are also commonly used alongside piston seals, to reinforce the seal and ensure that it stays in the correct position.

If you require any further advice on selecting the right Piston Seal for you, our knowledgeable team would be happy to help.

FPE Seals stock and supply a comprehensive range of Piston Seals, Piston Rings and Cylinder Parts.

If you are are unable to find what you are looking for on our web store, please let us know. Our inhouse manufacturing team can create seals to specification, in a wide range of materials to best meet your requirements.

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Question 15

Why Is My Excavator So Slow?

Accepted Answer

Tim Bone, Cylinder Parts Manager, FPE Seals explains some of the reasons why an excavator can be operating slowly.

“Modern day excavators come in many shapes and sizes, with most now fitted with more than one hydraulic pump, along with various system relief valves, service relief valves and priority valves to make the excavator run more smoothly.

Generally, there are two main hydraulic pumps, one for each of the track motors and possibly a smaller displacement pump for the pilot circuit. Reasons as to why an excavator is running slowly, can be down to the two main hydraulic pumps, as it is these that are primarily designed to power the main function of the excavator.

An excavator’s load is spread equally across both pumps. On its return, flow it is diverted through a loading valve or regeneration valve, combining both flows and giving the extra power needed to the required cylinder, resulting in a better tear out force.

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Check the power

An excavator’s two power supplies, the engine and the hydraulic pumps, are driven through a flexible drive coupling. The first signs of a problem will show when an excavator tracks to one side or some of the functions are slow, while others are working normally. If all the functions are slow then this might be a sign that the power unit has a fault, or the drive coupling is worn and slipping.

First check the power unit. Is the engine struggling? Do the revs of the engine increase under load or do they die off as though the engine is struggling to increase its power band?

Basically, if the engine is not running correctly or in need of a service, then it cannot provide the necessary power for the hydraulic pumps to supply the flow to run the system.

Engines need to be serviced regularly. Diesel filters need to be kept clean and free from contamination. Remove and replace the air filter if this has got very dirty.

Secondly, check the flexible drive coupling. This could be worn, shattered or even slipping on the drive shaft. Drive couplings wear out as the rubber segment that gives it the flexibility take a lot of stress. Also check the hydraulic fluid levels, if the suction strainer is blocked this can cause cavitation and starvation to the pumps.

Process of elimination

Finding a fault on any machine is time consuming, but using a process of elimination component by component will make a diagnosis easier. Try not to think that the problem is a major component, in the majority of cases it is often something very simple like an O-ring or a damaged seat of a valve.”

FPE Seals provide hydraulic seals and cylinder parts for excavators, contact our knowledgeable team today who will help find you what you need.

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Question 16

The History of Hydraulics: Then to Now

Accepted Answer

Hydraulics is the technology and applied science, that uses fluid for power.

The first hydraulic systems date back thousands of years, with irrigation and water clocks being used by ancient Greeks and Egyptians, as early as 600 BC.

The Persian Empire, Roman Empire, Ancient Greek, Chinese and Arabic societies that followed, each brought their own early innovations of hydraulic machinery, such as watermills, water wheels, water turbines, mining equipment, and the first known steam engine (known as an Aeolipile).

DID YOU KNOW?

The word "hydraulics" originates from the ancient Greek word "hydraulikos" meaning water (hydor) pipe (aulos).

Hydraulic technology has come a long way since then and can be found being used in a wide variety of applications every day, across the world.

Pascal's Law

Pivotal in setting the foundations for all modern hydraulics, was gifted French mathematician, physicist, and philosopher Blaise Pascal.

In 1640's, while studying hydrodynamics, he discovered a mathematical equation, known as 'Pascal's Law', which pronounced the principle of transmission of fluid pressure.

Pascal's law realised that pressure on a fluid in a confined area, remains constant in all directions and that this force could be harnessed.

Bernoulli's Principle

Nearly a 100 years later in 1738, Swiss mathematician and physicist Daniel Bernoulli put Pascal's fluid power discovery to use by pressurising water in pumps and mills using Bernoulli's principle.

First Hydraulic Press & the Industrial Revolution

Engineers soon began experimenting with functions of the principle described in Pascal's Law. One such engineer was Englishman Joseph Bramah, who in 1795 patented a design for a hydraulic press, paving the way for the industrial revolution.

The press used a hydraulic cylinder to harness fluid power to generate a compressive force, which then was used to produce mechanical force. This was used to automate all types of manufacturing and heavy-lifting equipment, such as printing presses, cranes, and machines that involved cutting, stamping, and crushing.

From water to other fluids

While water was the first hydraulic fluid ever used, engineers soon discovered that there were better options out there, to best suit specific applications.

Oil was regarded as a better alternative for pumps and motors, as compared to water it was non-corrosive, lubricated the components, and could handle high temperature and pressure better.

Nowadays, there are a whole host of different fluids being used in hydraulics systems. Hydraulic fluids are selected based on their compatibility with the operating conditions of the application, considering qualities such as the fluid's density, viscosity, and response to heat and pressure.

Modern day hydraulics

Fast forward to modern day, hydraulic systems are used all over, in a variety of ways. From heavy plant and mining machinery, to agricultural equipment and manufacturing facilities, through to deep sea, marine and automotive applications, to hand tools and household appliances, the list goes on and on.

Innovation in the field of hydraulics continues, with new hydraulic systems and equipment being designed and tested every day.

If you need any advice regarding your hydraulic cylinder design, or help to source the seals and metal parts needed, please contact FPE Seals knowledgeable team, who would be happy to help.

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Question 17

What are Oil Seals?

Accepted Answer

Oil Seals, also known as fluid seals, grease seals, dirt seals, shaft seals, or lip seals, help to seal the gap between static and moving components in machinery and equipment. Oil Seals used in rotating applications are known as rotary seals.

These seals are more commonly used in pumps, motors both electric & hydraulic, gearboxes & occasionally dirt wipers in hydraulic cylinders. They help protect shafts and bearings from dirt and harmful contaminants entering the internals of the application that they are fitted too, as well as prevent any leaks of lubricant.

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How are Oil Seals made?

Generally, an oil seal is made up of an outer circular metal part and a bonded inner flexible material (often nitrile rubber) that does the actual sealing.

The sealing effect is achieved by manufacturing a smaller inside diameter than the required shaft size, which preloads the sealing lip. A garter spring is often used to ensure a constant force on the shaft.

Nitrile rubber offers good durability for general use, while the flexibility of the spring behind the sealing lip keeps the oil seal firmly in place against the moving part.

How to Choose the Right Oil Seal

There are several key factors to consider when selecting the right oil seal to best protect your application.

1. Pressure: Many oil seals are used in high-pressure applications, so understanding the working pressure of your components is very important.

2. Temperature: Just like pressure, it is very important to choose the right seal that can withstand extreme heat or cold temperatures, depending on the operating environment of your application.

3. Fluid types: Oil seals interact with oils, fuels, grease, water and more. Choosing a seal material that is most compatible with your chosen medium can help to increase the durability of the seal and its internal components.

FPE Seals range of Oil Seals:

FPE Seals offer a comprehensive selection of Oil Seals and Rotary Seals in a range of different styles, materials, and sizes to best meet your needs.

Available to order online today.

Can’t find what you are looking for or require something more customised?

Our experienced in-house machined seals team can design and manufacture what you need in a wide range of standard and specialist materials, including NORSOK M-710 approved materials suitable for the Oil & Gas industry.

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Question 18

What is the difference between hydraulic and pneumatic applications?

Accepted Answer

Engineering and automation industries, generally rely on applications that are powered by either electric, hydraulic, or pneumatic systems.

Hydraulic and pneumatic applications are very similar in that they both channel mechanical energy using similar components. The main difference between the two is the medium used to transmit the force.

Hydraulics are pressurised liquids like oil, water, or synthetics. Whereas pneumatics operates by using easily compressible air or gases.

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difference between hydraulic and pneumatic applications

When it comes to maintaining the pressure of either liquids or gases, sealing plays an important role.

The difference between Hydraulic seals and Pneumatic seals

Hydraulic seals and pneumatic seals are the same in application but totally different in construction. Hydraulic seals are designed to work in a harsher environment and to withstand moveable forces. Whereas Pneumatic seals must be more flexible and have a less friction application due to operating at lower pressures.

Both hydraulic and pneumatic seals are used across a wide range of industries including but not limited to construction, plant, manufacturing, oil & gas, automotive, pharmaceutical, and food & beverage production.

FPE Seals stocks and manufactures a full range of sealing solutions and metal parts for both hydraulic and pneumatic applications. From piston seals, wiper seals, O-rings, and cylinder components.

Order online today or get in touch with our knowledgeable team here at FPE Seals, who will discuss your requirements based on your application, and help you find the right seal for the job.

When choosing the right type of seal, to ensure the safe and optimum performance of your machinery, seal material plays a big factor.

Not sure what you need? The FPE Seals team is happy to advise or download our Fluid Compatibility Table for guidance.

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Question 19

What are couplings used for?

Accepted Answer

The word “coupling” can be used to describe a range of different components in the field of engineering.

There are mechanical couplings as found on drive shafts connecting two units together, as well as threaded couplings, to name but a few. In this blog we discuss Hydraulic Couplings used in the fluid power sector.

There are many different types of Hydraulic Quick Release Couplings available on the market today. Selecting the best coupling for a particular application is extremely important.

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Selecting the right coupling for your application

There are many things you will need to consider that centre around the operating conditions it will be exposed to, such as:

• Flow rate of the equipment being used
• Flow rate of the hydraulic power unit
• Working environment e.g. Construction, Agricultural, Marine
• Ease of connection under pressure
• Cost

FPE Seals offers a range of couplings:

Flat Face Couplings: These couplings allow for minimal inclusion of contaminants during connection and prevent fluid loss and come with a unique locking method. Typical applications include excavator hammer circuits, hydraulic hand tools and breakers, mobile equipment, general industrial, mining, and agricultural.

Quick Release Couplings: Various quick release couplings are commonly used in fuel systems, cooling, test rigs, air tools, and agriculture.

ISO A Poppet valves have balanced springs and a locking ball system that allows quick connection, by pulling back the locking ring, Traditionally, a very versatile coupling, used in lots of equipment, these are now becoming more outdated, and in some cases, flat faced couplings may be a better option.

FPE Seals stocks and manufactures a full range of sealing solutions and metal parts for both hydraulic and pneumatic applications.

Our knowledgeable and experienced Cylinder Parts team can offer advice to help you select the most appropriate component to suit your application.

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Question 20

What is the Difference Between Gaskets & Seals?

Accepted Answer

Choosing between seals and gaskets can be confusing, as in many ways they essentially do the same thing. But there are some important differences to note, when deciding which is right for your specific application.

Gaskets provide a seal between static flat components like joints and flanges, while seals are used on active applications with significant movement between components as a result of rotation or reciprocation such as rotating shafts, pistons and pumps.

What is a Gasket?

Gaskets are used in static applications; the primary function of a gasket is to prevent leaks and over compression. Normally, a gasket is used to seal two mating surfaces that have a machined finish and space is limited.

Gaskets can be used for applications where there is an aggressive environment, substance, or liquid present. These are more commonly used in industries such as oil and gas, pulp and paper production, agricultural equipment, and transportation.

What is a Seal?

Seals help to prevent leakage in dynamic applications between two moving parts and prevent dirt or contaminants entering the system.

There is a broader range of seal types and profiles such as rotary seals, pneumatic seals, wiper seals and piston seals. Which are more commonly found in applications like hydraulic rams, motors, engines, pumps, and rotary shafts

Typically, seals are used in industries such as construction, manufacturing, food & beverage production, oil & gas, automotive and agriculture.

What are gaskets & seals made of?

Gaskets and Seals are manufactured in a range of materials.

These include Nitrile, Flourosilicone, Polyisoprene, Neoprene, Polyurethane, Silicone, Synthetic Polyisoprene, Thermoplastic Rubber (TPR) and Viton® depending on the application and working environment.

Let the experts at FPE Seals help you find the right seal or gasket for your next project.

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Can’t find what you are looking for or require something more customised?

Our experienced in-house machined seals team can design and manufacture what you need in a wide range of standard and specialist materials.

Question 21

What Causes Hydraulics Cylinders to Leak?

Accepted Answer

Almost all hydraulic cylinders within their working lifetime will show signs of a leak. However, if issues are spotted early enough leaks can be minimised and easily fixed.

Here we look at some of the main causes of hydraulic cylinders leak and how to prevent them.

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How to spot an internal hydraulic leak in a cylinder.

If you notice a pressure change in your hydraulic cylinder, or the cylinder starts to drop under its own weight, chances are there is internal leakage across the piston seal. Fluid that leaks into other areas of the cylinder, affects the motion of the rod. This causes the movement of rod in the cylinder to slow down, as it disperses the fluid to get back into the open position.

Another tell-tale sign of a leak, is a visual leak and having to replenish the hydraulic fluid in your machine more frequently than usual, causing an increase in your operating costs.

Main causes of a hydraulic cylinder leak

Wear & Tear

A worn or damaged Piston seal or cylinder component can cause fluid leakage. Even the tiniest of cracks can cause hydraulic fluid to enter other parts of the system.

Although the wear is unlikely to be visible without closer inspection, a drop in the machinery’s performance is usually an indicator that there is a problem within the cylinder, and its individual parts should be assessed.

Contamination

Dirt, debris, or small pieces of metal that break off other parts of the machine and enter the system can damage components within a hydraulic cylinder and cause an internal leak.

Contaminated hydraulic fluid such as water can cause a white milky fluid, which invariably results in corrosion. Some biodegradable oils if not changed regularly at service intervals can break down and cause sludging and components to stick.

Ensuring that your cylinder is kept well lubricated and protected from external contaminants will prevent this problem from occurring. If you suspect your hydraulic fluid is contaminated, you should flush and replace the fluid as quickly as possible.

Poor maintenance

Problems can occur if the individual components of a hydraulic cylinder have been poorly fitted or maintained. For instance, if seals are fitted incorrectly or over-tightened this can cause the seal to crack and lead to the deterioration of other parts over time.

Ensuring the cylinder is properly fitted by a skilled engineer and kept regularly lubricated, will prevent this from happening.

Changes in operating conditions

Exposure to high temperatures, or heat from high-speed or overuse can damage the seals and O-rings within your hydraulic cylinder and cause it to leak.

Therefore, it is vital to take a machine’s operating conditions into account when selecting the right seals and parts for your cylinder. Some applications require seals manufactured in materials that can withstand high temperatures and high pressure.

Replacing hydraulic cylinder seals and parts

FPE Seals provide replacement parts for all hydraulic cylinders and specialise in providing sealing solutions for aftermarket applications.

View what is on offer on our website or contact one of our knowledgeable team today who are happy to advise on finding you the best part for the job.

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Question 22

What are Hydraulic Cylinders used for?

Accepted Answer

Hydraulic cylinders have a variety of uses and can be found in machinery and equipment across many different industries including construction, agriculture, manufacturing, earth-moving and mining, food and beverage processing and packaging, deep sea, marine, and transportation.

In general, hydraulic ram cylinders are used in applications that lift heavy loads, push, pull or rotate, or in equipment such as hydraulic presses, which use pressurised fluid to exert force on an object.

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How do hydraulic cylinders work

Hydraulic cylinders use fluid from an external pump driven by a power unit.

Cylinders are designed based on the on the rule that liquids are incompressible. The result therefore being that when a force is applied at one point of a cylinder, the liquid will transfer an equal force at another point.

Most common hydraulic devices work by using a hydraulic pump, a reservoir for fluid storge to the pump. Mechanical energy is converted to hydraulic energy, moving the liquid through a system. Valves are used to regulate the flow of the liquid and control the pressure of the device. A hydraulic cylinder then converts the hydraulic energy back into mechanical energy.

They are used to lift heavy loads

Hydraulic cylinders can push, pull, and lift loads of any description. Commonly, they are used in mobile applications, such as excavators, loaders, graders, dumper trucks, backhoes or dozers, or any mobile machinery that requires a linear motion to move loads.

They are used in industrial machinery or equipment

Hydraulic cylinders are commonly found in industrial settings where large amounts of power are needed to operate machinery. This makes them ideal for use in many industrial applications such as presses, compactors, and injection moulding to name but a few.

They are used to operate machines

Many industries used hydraulics to power their machinery and equipment. For example, the food and beverage industry sources power from hydraulic cylinders to process, position and package food and drink products.

The agricultural sector extensively uses hydraulic-powered machines such as tractors, loaders, spraying equipment, skid steers, balers and harvesting equipment, to plant and harvest crops and rear livestock.

But these are just a couple of examples, hydraulics can be found across a multitude of industries, for a variety of uses from the largest of industrial equipment to the smallest of hand tools.

FPE Seals stocks and manufactures a full range of sealing solutions and metal parts for hydraulic cylinders. From piston seals, wiper seals, O-rings, and cylinder components.

Order online today or get in touch with our knowledgeable team here at FPE Seals, who will discuss your requirements based on your application, and help you find the right seal for the job.

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Question 23

What are four major factors you need to consider when choosing adhesives?

Accepted Answer

Different adhesives have different properties, allowing them to be used in many different circumstances. As such, the type of adhesive you need will depend on the type of project you’re working on and what your ultimate goal is.

There are several key factors to bear in mind when choosing adhesives. To help you choose the right adhesive for your specific job, we look at four factors you should consider.

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The Type of Surfaces You’ll Be Bonding

A major factor to consider when choosing adhesives is the surfaces you’ll be bonding together. This will help you determine which type of adhesive is best for your project.

For example, if you’re bonding rubber to metal, you’ll want to use a rubber-toughened superglue. If you’re joining glass, you’ll want to use a special adhesive designed for glass.

There are various types of adhesives for different surfaces. For example, there are adhesives suitable for wood, plastic, glass, and metal. There are also adhesives for specific materials like ceramics and fabrics. There are even specialty adhesives for specific projects like hydraulics, plumbing, gardening, and repairs.

The Adhesive’s Working Life

When choosing adhesives, you will also need to consider the adhesive’s working life. This refers to the amount of time you have before the adhesive dries and bonds the two surfaces together.

Depending on the project and adhesive you’re using, you may have anywhere from a few minutes to a few hours before the adhesive is completely set. This is something to keep in mind because it’ll help you determine the best way to approach the project.

For example, if you’re using a general adhesive and you have only a few minutes before the surface is dry and fully bonded, you’ll need to work quickly. On the other hand, if you have a few hours before the two surfaces are fully bonded, you’ll need to approach the project more methodically.

How Much Weight the Adhesive Can Hold

Depending on the project you’re working on, you may need to know how much weight the adhesive can hold. This is especially important if you’re using an adhesive to join materials together that will be used to hold heavy objects.

For example, if you’re joining industrial materials together, you’ll want to use an adhesive that is rated for heavy-duty applications. This way, you can rest assured that the materials will stay bonded together even under heavy pressure.

Additional Options and Recommendations

With each adhesive, you’ll find a range of specific additional options and recommendations, it is important that you always follow the product’s instructions and guidelines. This will ensure that you get the most out of the product and that is used safely.

For instance, certain adhesives work best when used outdoors. Every type of adhesive will have a recommended drying time you must follow. Some adhesives will be incompatible with specific materials.

Choosing the right adhesive for your project can be a daunting task. This is because there is a wide range of different adhesives to choose from, each with its own set of advantages and disadvantages.

To make the process easier, you’ll need to consider all the above, however, if you are still unsure it is always best to speak to an industry expert or to contact the provider directly.

FPE Seals supplies a range of adhesives suitable for a wide range of industries including hydraulics, pneumatics, automotive, manufacturing, industrial, and medical equipment.

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Question 24

Why do hydraulic cylinders creep, and how to prevent it?

Accepted Answer

Hydraulic cylinder creep is a common issue, that can occur when a hydraulic cylinder fails to maintain its position. This can be caused by a variety of factors, including internal leakage within the cylinder caused by damaged or worn seals, or improper fluid viscosity.

To prevent hydraulic cylinder creep, it is important to regularly maintain and inspect the cylinder and the hydraulic system, and to use the most compatible fluid.

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Never ignore the signs of hydraulic cylinder creep

Ignoring the signs of hydraulic cylinder creep can lead to several serious problems. For one, the cylinder may fail to maintain its position, which can cause dangerous situations depending on the application. For example, if the cylinder is used in a lifting application, it may drop the load it is holding, potentially causing injury or damage to property.

Additionally, ignoring the signs of hydraulic cylinder creep can cause damage to the cylinder and the rest of the hydraulic system, leading to costly repairs or replacement.

Regular maintenance and inspections can help to prevent hydraulic cylinder creep and ensure that the system is functioning properly.

How to prevent hydraulic cylinder creep?

There are several steps you can take to prevent hydraulic cylinder creep. Here are a few tips:

Overall, regular maintenance and attention to detail are key to preventing hydraulic cylinder creep. By taking these steps, you can help to ensure that your hydraulic system is functioning properly and can avoid costly repairs or downtime.

Looking for a replacement part for a hydraulic cylinder, either for service or repair work or an engineering design project but unsure where to start?

Contact us today, our experienced and knowledgeable team can offer technical support and advice with your cylinder design and help you find the right part for the job.

Whether you are after something off-the-shelf or something custom made, we offer OEM quality products at aftermarket prices, are quick to respond, have a wide range of stock on hand, as well as an in-house manufacturing capability.

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Question 25

What is a hydraulic cylinder and how are they used on excavators?

Accepted Answer

Hydraulic cylinders are used effectively in a variety of applications to move heavy loads. This is because of their ability to generate large amounts of force using pressurised fluid, with relatively small amounts of input power.

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Different applications of hydraulic cylinders.

Some common applications for hydraulic cylinders include:

• Construction: used in plant and earth-moving equipment, such as excavators and bulldozers, to power the movement of the boom, dipper and bucket cylinders . Tracking the excavator back & forth.

• Manufacturing: used in production and processing equipment, such as stamping and pressing, to apply large amounts of force to shape or cut materials.

• Agriculture: used in farming equipment and machinery for services such as transportation, planting, feeding, drilling, cultivation and harvesting.

• Food and Beverage: used in wide variety of equipment to process and package food and drinks.

• Automotive: to power the brakes, steering and suspension systems in certain vehicles.

• Aerospace: used in aircraft to power the movement of the flaps, landing gear, airstairs and other control surfaces.

How do they work?

Hydraulic cylinders in an excavator work by using pressurised hydraulic fluid to generate a force that can be used to manoeuvre the excavator and move the boom, dipper and bucket. The control valve is used to control the flow of fluid into the cylinder, allowing the operator to move the boom, dipper and bucket with precision.

Typical cylinders found in Excavators & Mini-Excavators.

There are different types of cylinders found on excavators and mini excavators, each with its very own specific function.

1. Bucket cylinder: These cylinders are used to power the movement of the bucket, that is located on the end of the dipper arm. Bucket cylinders are typically smaller than boom cylinders and are used to move the bucket and to control its angle during excavation.

2. Boom cylinder: These cylinders are used to power the movement of the main boom, up & down. Boom cylinders are typically larger and more powerful and can generate significant amounts of tare out force to move the boom when working.

3. Dipper cylinder: The Dipper arm cylinder, also known as the stick or crowd it is used to power the movement of the arm which carries the bucket.

4. Rotary Unions: This unit is used transfer fluids from the excavator to the undercarriage of the machine. This allows the operator to change the direction the excavator is facing, which is important for manoeuvring the bucket in different directions or for dumping material.

5. Swing cylinder: A swing cylinder also known as a slew cylinder, is a hydraulic cylinder that is used in excavators to offset the upper part, of the boom about a vertical axis. This allows the operator to change direction, which is important for manoeuvring the machine in tight spaces or when digging in different directions.

6. Track Adjuster: The track adjuster is typically located in the undercarriage of the tracks and consists of a hydraulic cylinder that is connected to the track frame. When the cylinder is extended by pumping grease into the cylinder it adjusts the tension in the tracks.

7. Dozer: A dozer cylinder, also known as a blade cylinder, is used on mini excavator to raise and lower the dozer blade. The dozer blade is used to push or move materials, such as dirt, sand and helps in assisting the stability of the excavator.

8. Vari Width cylinder: This cylinder is fitted in the undercarriage to move the tracks in & out. On smaller excavators, this helps to increase the stability and allows the excavator to manoeuvre through narrow gaps greater than 900mm.

FPE Seals provide aftermarket replacement seal kits at OEM quality, for the hydraulic cylinders on an excavator, for 1000's of leading plant and engineering brand's equipment models.

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Question 26

How did tractors impact the agricultural industry?

Accepted Answer

Prior to the invention of the tractor, farmers primarily relied on horses and other draft animals to plough fields and perform other tasks. The tractor, with its internal combustion engine and hydraulic system, was able to replace the work of many animals, allowing farmers to cultivate more land and produce more crops.

In this blog, we discuss the history of the tractor and how the use of hydraulics has transformed farming.

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History of the tractor

The history of the tractor dates to the late 19th century when inventors began experimenting with steam-powered and gasoline-powered engines for use in agriculture.

The first successful gasoline-powered tractors were developed in the early 1890s, with the most notable being John Froelich's "Froelich tractor" which was built in 1892.

During the early 20th century, many companies began to produce tractors, including the Fordson, which was first produced by Henry Ford in 1917. The Fordson, along with other tractors of the time, such as the International Harvester and Allis-Chalmers, were primarily used for ploughing and other tillage tasks.

In the 1920s and 1930s, tractors became more versatile, with the development of models that could be used for a variety of tasks, including planting, harvesting, and hauling. The introduction of rubber tyres and power take-offs (PTOs) also greatly increased the versatility and efficiency of tractors.

In recent decades, tractors have continued to evolve and improve, with the introduction of new technologies such as hydrostatic transmissions, electronic controls, and GPS systems. Today, tractors are an essential part of modern agriculture and are used in a wide range of applications, including large-scale commercial farming, small-scale subsistence farming, and even in construction and landscaping.

How hydraulic systems are used by the agricultural industry

Hydraulics are widely used in agriculture for a variety of applications, including:

1. Tractor operation: Tractors use hydraulic systems to control their movements, including steering, lifting, and lowering.
2. Harvesting machinery: Hydraulics are used in combine harvesters, balers, and other harvesting equipment to control their movements and adjust the speed and flow of material being processed.
3. Irrigation systems: Hydraulic systems are used in centre pivot irrigation systems to control the movement of the sprinkler and regulate the flow of water.
4. Plough and cultivators: Hydraulic systems are used in plough and cultivators to control the depth and angle of the blades.

Benefits of using hydraulics for agriculture

Hydraulics bring several benefits to the agricultural industry, including:

1. Precision control: Hydraulic systems provide precise control of movement and power transfer in farm machinery, enabling accurate and efficient operations.
2. Increased efficiency: Hydraulics allow for smoother and consistent operation of machinery, reducing downtime and improving productivity.
3. Durability: Hydraulic systems are designed to withstand harsh conditions, reducing wear and tear on equipment, and extending its lifespan.
4. Safety: Hydraulics offer greater safety for operators, reducing the risk of injury or accidents while working with heavy machinery.
5. Versatility: Hydraulic systems can be easily adapted to different types of farm machinery, making it a versatile and cost-effective solution for the agriculture industry.
6. Comfort: Hydraulics provide a more comfortable working environment for operators, reducing fatigue and improving their overall experience.

In need of hydraulic cylinder seals and parts?

FPE Seals have been trusted supplier for agricultural customers for many years and have a particular expertise in providing sealing solutions and hydraulic cylinder parts for aftermarket equipment and machinery used in this sector.

View what is on offer on our website or contact one of our knowledgeable team today who are happy to advise on finding you the best part for the job.

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Question 27

How to prevent hydraulic cylinder cavitation

Accepted Answer

Cavitation is the formation of vapour bubbles in a flowing liquid. When the bubble rapidly collapses, it produces an intense shock wave that rapidly erodes contact surfaces. If a pump suffers from cavitation, it will be very noisy and suffer from early failure.

Should this take place within a hydraulic system, it can bring about a cascade of harmful issues that can eventually ruin essential (and expensive) components, resulting in system failure. While most people identify cavitation problems with pumps and motors, cavitation can also occur in hydraulic cylinders.

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Problems caused by cavitation in a hydraulic cylinder.

• Damage to hydraulic components: The air bubbles formed during cavitation can damage hydraulic components such as pumps, valves, and cylinders by erosion or pitting the surfaces they come into contact with.

• Noise: Cavitation can generate loud noises, which can be annoying for operators and can potentially damage hearing if exposed to for an extended period of time.

• Premature Seal Failure: Cavitation can cause the seals within a hydraulic cylinder to wear, erode, or deteriorate, causing premature seal failure.

• High fluid temperatures: Cavitation can cause fluid temperature to rise above 180° F (82° C) which can damage seals and accelerate degradation of the fluid. In turn reduces the service life of the hydraulic system.

• Fluid contamination: Cavitation can cause the release of debris and other contaminants into the hydraulic fluid, which can lead to further damage to the system and reduce efficiency.

Preventing Cavitation

• Inspect and replace worn components on a regular basis: Regular inspections of the hydraulic cylinder can help identify any worn or damaged components that need to be replaced.

• Keep the hydraulic system clean: Clean the hydraulic system on a regular basis to prevent contamination from dirt or other debris. To avoid contamination, it is also critical to use high-quality hydraulic fluid.

• Align components properly: Make sure that all hydraulic cylinder components are properly aligned to prevent uneven movement.

• Monitor hydraulic pressure: Keeping hydraulic pressure within the recommended range can help prevent excessive pressure.

• Remove air from the hydraulic system: Bleed the hydraulic system on a regular basis to ensure that there is no air in it. This will prevent the piston from moving unevenly because of the compressibility of the air.

Looking for a replacement part for a hydraulic cylinder, either for service or repair work or an engineering design project but unsure where to start?

Our experienced and knowledgeable team can offer technical support and advice with your cylinder design and help you find the right part for the job.

Whether you are after something off-the-shelf or something custom made, we offer OEM quality products at aftermarket prices, are quick to respond, have a wide range of stock on hand, as well as an in-house manufacturing capability.

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Question 28

How do I know if my pneumatic seal needs replacing?

Accepted Answer

Pneumatic Seals are used in a wide variety of applications across haulage, construction, plant, pharmaceutical, food, and general engineering industries, improving equipment performance. They are designed to keep the gases and fluids under pressure, helping to maintain a controlled and efficient system.

Depending on the application, pneumatic seals come in a variety of shapes, sizes, and materials. FPM/Fluorocarbon rubber, nitrile, silicone, EPDM, and PTFE are some of the most popular materials used for pneumatic seals. However, overtime pneumatic seals can wear out or become damaged, compromising the pneumatic system's performance. In this blog, we will discuss some signs that indicate pneumatic seals need to be replaced.

How to know if your pneumatic seal needs replacing?

Air Leakage:

One of the most obvious signs pneumatic seals need to be replaced is air leakage, either externally or internally. The most common areas where leaks can occur include joints, couplings, seals, and fittings, as well as hoses and areas that have worn packing. Air is usually audible and you may also notice a drop in system pressure.

Reduced performance:

Another sign that your pneumatic seal needs replacing is reduced performance. This could be due to seals no longer functioning as they should. Reduced performance could also cause a slower response time or a loss of power from the system such as slow or uneven movement of the pneumatic cylinder or a decrease in the force it exerts.

Wear and Tear:

As a result of being exposed to harsh operating conditions such as high temperatures or chemicals, pneumatic seals are likely to wear and tear and can get damaged over time. Any pneumatic seals showing signs of damage, such as cracks, tears, or deformations, should always be replaced.

Contamination:

Contamination is another reason pneumatic seals fail. If the system is exposed to dirt, dust, or other debris, it can damage the seal and cause it to fail. If you notice any contamination, such as debris on the seal or in the system, it is important to clean it thoroughly and replace the seal.

Extreme Temperature:

The temperature range, of pneumatic seals is -4°F to +176°F, anything that is operating out of this range is susceptible to failure when operating in extreme temperatures. This causes the seals to become brittle and crack. It is essential when choosing the appropriate medium that it is suitable to withstand the working temperature range of your pneumatic cylinder.

Age of the seals:

Pneumatic seals have a limited lifespan, and over time they will eventually need to be replaced. The lifespan of pneumatic seals can vary depending on a few factors, including the operating conditions of the system, the quality of the seals, and the level of maintenance the system receives. It is recommended that pneumatic seals be replaced every 2 to 3 years, or sooner if any of the above signs are present.

At FPE Seals, we offer a wide range of high-quality pneumatic seals and offer advice and guidance to help you find the part you need.

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Question 29

5 Reasons Why a Hydraulic Cylinder Won’t Work

Accepted Answer

Hydraulic cylinder failure causes downtime in operations. This situation is not only inconvenient in terms of maintenance but also takes time to troubleshoot the problem.

Being aware of the most common issues related to operating hydraulic cylinders can help prevent problems from occurring and keep systems running smoothly. In this blog post, we will discuss some of the reasons why a hydraulic cylinder won't work.

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Reasons Why Hydraulic Cylinders Stop Working:

1. A seal is worn or damaged

Seals gradually degrade over time and if not replaced hydraulic fluid leaks might occur. Due to insufficient fluid in the system, cylinders may become erratic in movement causing instability. Additionally, worn seals can cause misalignment between the cylinder rod and seal, causing the cylinder to operate inefficiently.

2. Lack of system pressure

To safeguard the hydraulic system, a hydraulic relief valve is used to regulate the pressure. One of the main reasons why a hydraulic cylinder won't work can be due to the system pressure or flow from the pump, being too low due to worn components. This can be solved by checking system pressure regularly.

3. The cylinder is damaged

A damaged cylinder can result in reduced system performance, loss of hydraulic pressure, fluid contamination, and fluid leakage, all of which can prevent it from working. Therefore, it is important to perform regular maintenance and inspections to ensure cylinders are in good working condition.

4. The cylinder rod is bent

A typical reason why a hydraulic cylinder is not working is due to a bent rod. Which has occurred due to its operation or abuse. Or if it is impacted by heavy objects or machinery, this can cause damage to the cylinder rod.

If you notice any signs of wear or deformation in the rod, it is important to replace it right away. This is not just to fix the problem, but also to make sure it does not cause any accidents or damage to your equipment.

5. Hose failure

The purpose of hydraulic hoses is to allow hydraulic fluid to flow from one component to another. Hoses are the means by which fluid is transferred freely and keeps vital parts of hydraulics systems moving. A damaged hose, results in leaking pressurised fluid. This can result in a loss of pressure in the hydraulic system, which can cause equipment to malfunction or stop working altogether. It is important to regularly inspect hydraulic hoses for signs of wear or damage.

In summary, the simplest way to avoid problems with a hydraulic cylinder is to perform regular inspection, and servicing, which can reduce the requirement for expensive repairs and downtime.
If you would like any advice on sourcing replacement metal parts or seals for your hydraulic ram, please contact our helpful and knowledgeable team today.

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Question 30

What are Bonded Washers or Dowty Seals?

Accepted Answer

Bonded Washers, also known as Dowty Seals or Bonded Seals, offer a powerful solution for achieving tight, leak-free connections in various applications. They are typically used in industries such as automotive, hydraulics, and pneumatics.

These seals are comprised of a metal washer and a rubber ring, which is bonded inside the diameter. The two components work together to create a dependable and leak-free connection. Bonded Washers are primarily designed to withstand high-pressure applications, making them a popular choice in hydraulic systems.

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Properties and Materials:

The construction of Bonded Washers is simple yet effective. The metal washer, often made of steel or stainless steel, provides structural integrity, and prevents deformation under pressure. The rubber ring, typically made of nitrile rubber or other elastomeric materials, forms the sealing element. Nitrile rubber is widely used due to its excellent resistance to oil, fuel, and hydraulic fluids. However, different applications may require seals made from other elastomeric materials, such as silicone or fluorocarbon rubber, depending on the specific operational requirements.

Working Principle:

The working principle of Bonded Washers relies on a combination of compression and the elastomeric properties of the rubber ring. When the seal is tightened, the rubber ring compresses between the washer and the mating surface, creating a tight and secure connection. The rubber material provides resilience and elasticity, allowing it to adapt to slight variations in the mating surfaces, ensuring a dependable seal even under dynamic conditions.

Advantages of Bonded Washers:

Leakage Prevention: Bonded Washers offer exceptional sealing capabilities, preventing fluid leakage in high-pressure environments. Their robust design and secure connection help to maintain system integrity, reducing the risk of costly leaks and downtime.

Vibration Resistance: The rubber ring in Bonded Washers acts as a damping element, absorbing vibrations and reducing the chances of loosening or failure due to dynamic movements.

Easy Installation: Bonded Washers are simple to install, making them a time-saving solution for engineers. With just a washer and a rubber seal, they can be easily integrated into existing systems without requiring complex tools or techniques. Bonded Washers are flexible, and so can fit in a variety of devices.

Cost-Effective: These seals offer a cost-effective solution due to their durability and long service life. Their resistance to wear, tear, and degradation ensures that they can withstand demanding environments without frequent replacements, reducing maintenance costs over time.

FPE Seals stock and supply a comprehensive range of Bonded Washers that can be used to seal bolt heads and prevent leakage from hydraulic fittings or adaptors.

Can’t find what you are looking for? Get in touch with our knowledgeable team today for further advice and information about our products including a full range of hydraulic ram components.

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Question 31

A Guide to Seal Materials

Accepted Answer

Hydraulic seals are used in industrial applications, that prevent a fluid or gas from passing between different components of a cylinder, ensuring that the system operates efficiently and safely. However, not all seals are created equal, and different applications may require different types of seals. In this blog, we discuss the factors to consider when choosing the right seal, that is created in the appropriate material, to best suit your application.

Selecting The Right Seal:

When selecting a hydraulic seal, it's important to consider its material and design, to ensure that it works effectively, safely and reliably.

Temperature:

Temperature is one of the most important factors to consider when selecting seals. The temperature range of the seal must be compatible with the operating environment. If the seal is exposed to temperatures outside of its range, it can fail prematurely.

The temperature range of a seal is determined by the material it is made from. Different materials have different thermal properties. Some materials, such as rubber, are good at sealing at low temperatures, while other materials, such as metal, are better at sealing at high temperatures.

In addition to the operating temperature, the seal must also be able to withstand the temperature fluctuations that may occur in the environment. For example, a seal that is installed in a climate-controlled environment may not be able to withstand the extreme temperatures that can occur outdoors.

High Pressure:

Not all seals can withstand high pressure. Therefore, if you are looking to seal a high-pressure application, it is vital to select a seal in a material that can cope without deforming or breaking. The seal design must be able to create a tight seal without creating too much friction and the seal must be lubricated properly to prevent wear and tear.

Some of the most common types of seals used in high-pressure applications include:

O-rings: O-rings are made of a flexible material that can conform to the surface of the seal housing. They are available in a variety of materials, including rubber, nitrile, and fluorocarbon.

V-rings: V-rings are made of a stiffer material than O-rings and can withstand higher pressures. They are also available in a variety of materials, including rubber, nitrile, and fluorocarbon.

Piston seals: Piston seals are used to seal pistons in cylinders. They are made of a variety of materials, including rubber, nitrile, and fluorocarbon.

Fluid compatibility:

If the seal is not compatible with the fluid used in a hydraulic system, it can degrade the seal material prematurely, causing the seal to leak. When evaluating fluid compatibility numerous factors need to be considered including the chemical composition of the fluid, the operating temperature and pressure, and the seal material. Compatibility will vary dependant on the material type. For example, elastomers are generally compatible with a wide range of fluids, while plastics and metals are more limited in their compatibility.

Different Seal Materials:

Nitrile (NBR)

Properties: Nitrile seals have a good resistance to elongation at break, abrasion and compression set, but their flexibility suffers somewhat in the lower temperature range. Seals made from this material have a low resistance to ozone and must be stored carefully in most environments.

Temperature: Nitrile can withstand temperature range from -30°C to +100°C

Fluid Compatibility: The most common nitrile copolymer blend is the compound known as Buna-N. Possessing very good resistance to petroleum based hydraulic oils, Buna-N also works well with fuels such as diesel or gasoline.

PTFE

Properties: PTFE has chemical inertness, high heat resistance, low temperature flexibility, low running friction, and non-adhesive characteristics. Because of a lack of resilience (memory) in PTFE, an energizer is most often employed to obtain the desired fit. Most PTFE seals, to retain their toughness and flexibility, are fortified with short glass fibres, bronze flashes, carbon graphite, or a combination of these fillers.

Temperature: PTFE can withstand temperatures to over 300°C but are often reduced by the filler or energizer employed.

Fluid Compatibility: PTFE seals are compatible with most chemicals, including acids, bases, and solvents.

Ethylene-Propylene (EPDM)

Properties: Ethylene-Propylene (EPDM) has good heat resistance, low compression set and good flexibility at low temperatures.

Temperature: Ethylene-Propylene temperature ranges between -45°C and +150°C .

Fluid Compatibility: Ethylene-Propylene can be used for sealing phosphate ester hydraulic fluids such as Skydrol but is not suitable for petroleum based fluid. Ethylene-Propylene is highly effective for use with steam, acetone, and dilute acids and bases. Specially compounded Ethylene-Propylene can be made suitable for automobile brake systems.

Polyurethane (AU)

Properties: Polyurethane is highly resistant to oil swell, ozone, oxidation, abrasion and has excellent cut resistance. Highly resilient, urethanes also have high tensile strength and elongation properties. Formulated of copolymers of ether or ester based urethanes, this material is used in a wide application of seals, wipers, backup rings, cushions, bumpers, and a myriad of other uses.

Temperature: Most urethane seals remain flexible and efficient in temperatures ranging between -54°C and +93°C with some able to withstand intermittent temperatures up to +135°C.

Fluid Compatibility: Polyurethane is compatible with hydraulic systems using petroleum based fluids.

Silicone (VMQ)

Properties: Silicone is an elastomer made from silicon, oxygen, hydrogen, and carbon. It has a high resistance to dry heat, ultraviolet light, and ozone. This material is not recommended for dynamic situations due to poor abrasion resistance and high friction characteristics.

Temperature: Silicone temperature ranges from -54°C to +204°C

Viton® - FPM / Viton® equivalent FKM

Properties: Viton® - FPM / Viton® equivalent FKM combines high temperature resistance with excellent chemical resistance. This material is not recommended for use in low temperatures or in aircraft hydraulic fluids.

Temperature: Viton® - FPM / Viton® equivalent FKM temperature ranges is -20° to +400° F.

Fluid Compatibility: Excellent for use with alcohol and aromatic fuels and highly resistant to ultraviolet light and ozone.

PolyEther Ether Ketone (PEEK)

Properties: PEEK has excellent strength, fatigue resistance and stability in high temperature environments, with a melting point around 343°C, and very good chemical resistance.

Temperature: PolyEther Ether Ketone (PEEK) recommended operating temperature is -54°C up to +260°C

Fluid Compatibility: PEEK is compatible with almost any of the solvents used in HPLC.

Hydrogenated Nitrile Butadiene Rubber (HNBR)

Properties: Hydrogenated Nitrile is also known as saturated Nitrile have excellent resistance to many modern fuels, resistance to high energy radiation & good abrasion resistance.

Temperature: Hydrogenated Nitrile Butadiene Rubber (HNBR) temperature ranges from -40°C to +150°C

Fluid Compatibility: HNBR is widely used in automotive and oil industries and maintains excellent resistance to motor oils, sour gas, amine/oil mixtures, oxidized fuels, and lubricating oils. HNBR is resistant to mineral oil-based hydraulic fluids, animal and vegetable fats, diesel fuel, ozone, sour gas, dilute acids, and bases.

Ultra high molecular-weight polyethylene (UHMWPE)

Properties: UHMWPE (Ultra High Molecular Weight Polyethylene) has very long molecular chains that helps to transfer load more effectively, strengthening intermolecular interactions. This results in a very tough material, with the highest impact strength of any thermoplastic presently made. It has very high abrasion resistance, shows zero water absorption, is self-lubricating and has a friction coefficient only slightly above most filled PTFE.

Temperature: Ultra high molecular-weight polyethylene (UHMWPE) recommended operating range is -200°C up to just +80°C

Fluid Compatibility: UHMWPE is stable in all hydraulic fluids, with high resistance to acids, bases, and aggressive media.

Selecting the right seal material is crucial to ensure the efficient and safe operation of machines, devices, and systems. Not sure what you are need? Get in touch with our knowledgeable team here at FPE Seals, who will discuss your requirements based on your application, and help you find the right seal for the job.

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Question 32

What are Static Seals?

Accepted Answer

Static seals are essential components used to prevent the leakage of fluids or gases between stationary surfaces. Unlike dynamic seals, which are used in applications involving relative motion between components, static seals remain fixed in place, creating a barrier between two non-moving surfaces. They are designed to maintain a reliable and leak-free interface under various operating conditions.

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How Do Static Seals Work?

Static seals use various materials and designs to fill the gaps and imperfections between the mating surfaces. When compressed between the two surfaces, they form a barrier that stops fluids or gases from passing through. The effectiveness of the seal is determined by factors such as material properties, compression, and force.

Types Of Static Seals

Gaskets: These are flat or profiled rings made from materials like rubber, cork, metal, or paper, commonly used to create a dependable, leak-free seal for applications such as engines, pumps, and pipe flanges.

O-ringsThese are circular rings made from elastomers such as nitrile, silicone, or Viton. They are commonly used in hydraulic and pneumatic systems.

Metal seals & Washers: These are typically made of copper, stainless steel, or aluminium, and are commonly used for high-temperature or high-pressure applications.

Lip seals: These are expertly designed to seal around a shaft or rod securely to prevent fluid or gas leakages. They are commonly used in engines, gearboxes, and hydraulic systems.

Diaphragms: These are flexible seals that move in response to changes in pressure or fluid flow. They are commonly used in pumps, valves, and regulators to ensure smooth operation.

Bellow seals: These are accordion-like seals that can expand and contract to accommodate changes in temperature or pressure. They are commonly used in valves, pumps, and other high-pressure applications.

Factors To Consider When Choosing Static Seals

When choosing static seals, several factors need to be considered to ensure they meet the specific requirements of the application and provide effective sealing. Here are the key factors to consider:

Material Compatibility: The seal material should be compatible with the fluids or gases it will meet. Different chemicals and environmental conditions can cause materials to degrade, swell, or become brittle, leading to seal failure.

Temperature and Pressure: Static seals must be capable of withstanding the operating temperature and pressure of the application. Higher temperatures and pressures may require seal that can handle the heat and pressure without breaking down.

Chemical compatibility: It is another key consideration when selecting static seals. Different materials are compatible with different types of chemicals, so it's important to choose a seal material that is resistant to the chemicals it will meet.

Size and Shape: The seal must fit accurately within the designated space and match the required shape. Custom seals might be necessary for non-standard applications.

Benefits Of Using Static Seals

Static seals offer several benefits in various engineering and industrial applications. Here are some of the key benefits of using static seals:

Leak Prevention: The primary function of static seals is to prevent the escape of fluids or gases, such as liquids, oils, gases, or chemicals, from one side of the seal to the other. By creating a reliable barrier, they help maintain system integrity and prevent contamination.

Cost-Effectiveness: Static seals are typically simpler in design and easier to manufacture compared to dynamic seals, which require more complex mechanisms to accommodate relative motion. This simplicity often translates to lower production costs.

Easy Installation: Since static seals do not require complex moving parts, their installation is often straightforward. They can be fitted in place with basic tools, reducing downtime during maintenance or repairs.

Wide Range of Materials: Static seals can be made from various materials, such as rubber, silicone, metal, plastics, or composite materials. This versatility allows the seals to be tailored to specific applications, considering factors like temperature, pressure, chemical compatibility, and environmental conditions.

Temperature and Pressure Resistance: Static seals are designed to withstand a wide range of temperatures and pressures, making them suitable for use in both low and high-pressure systems, as well as extreme temperature environments.

Reduced Wear and Tear: Static seals experience minimal wear compared to dynamic seals because they are not subject to friction and movement. This leads to longer service life and less frequent replacement, resulting in cost savings over time.

If you require any further advice regarding Static Seals and their applications, then our knowledgeable team at FPE Seals would be happy to help.

We stock, source, and supply a fully range of Static Seals. Can’t find what you’re looking for? We can also manufacture the seals to your specification, in a full range of materials to meet your exact requirements.

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Question 33

Why You Should Consider a Machined Seal?

Accepted Answer

When it comes to selecting the right seal for hydraulic ram repair, it’s not always a case of one size fits all.

With so many different types of hydraulic cylinders out there, being used on all different kinds of machines for a multitude of functions, identifying the problem and deciding on the appropriate steps to fix it, is just the start.

Sometimes it can be as easy (if repair work can be called easy!), as locating and ordering the correct repair or rebuild kits for the job. Ready-made seal kits or cylinders parts can be ordered and delivered by a trusted supplier, and in a lot of cases work can begin.

But what happens when metal work alterations to the cylinder, have made selecting something off the shelf a bit tricky? Or you’re faced with work being delayed, due to a long delivery time on standard parts? This is where a machined seal can help.

Benefits of a Machined Seal

A machined seal, is a bespoke seal, manufactured on a computerised seal production lathe. Depending on the lathe’s capabilities, virtually any kind of seal, for just about any application, can be produced.

The beauty of a machined seal is that you get exactly what you are looking for, quickly. It doesn’t matter on type of seal that you need either. Wiper, gland (rod), piston and rotary seals, as well as guide rings, back up rings and gaskets, can all be produced.

At FPE Seals, we have six manufacturing machines, that are capable of diameters of 4mm to 595mm and lengths of between 15mm to 39mm. One of which, has the additional tooling capability to include slots, drilled holes and milled profiles.

We can design and create just about any seal profile, in a full range of materials and will help advise on the best seal and material for the job in hand. No minimum quantity is required to place an order and we guarantee a quick dispatch, including a next day delivery service in the UK.

If you think we can help, contact one of our skilled advisors today.

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Question 34

What are hydraulic seals?

Accepted Answer

A hydraulic seal is a device or substance used between two or more components to prevent something from passing between them. They are found in many items in everyday use.

Why do we need seals?

Hydraulic and pneumatic cylinders operate by air or fluid being pumped into the cylinder at pressure. Because cylinders work at high pressure, there is lots of potential for air or fluid to escape between the different components, even through the very smallest of gaps.

Wherever the different cylinder components meet, if they are not welded, they will require sealing.

Types of hydraulic seals

There are six general types of seal that may be found in a hydraulic cylinder. They are:

Wiper, Scraper or Dust Seal
Rod Seal, Gland Seal or Neck Seal
Static Seal
Piston Seal
Wear Ring, Bearing Ring or Guide Ring
Rotary Seals

Where seals are positioned in a cylinder

The main purpose of a Wiper Seal in a cylinder is to prevent dirt and other contaminates from getting into the system. This is usually achieved by a wiping lip that points out of the cylinder.

Piston Seals are designed to seal between the piston and the cylinder, sealing dynamic pressure to allow the cylinder to extend and retract.

Rod Seals are designed to seal between the rod and the gland.

Rotary Seals as their name suggests, seal against a dynamic surface that is rotating.

Static Seals are a wide variety of seals that seal against only static surfaces.

Guide Rings prevent contact between two moving surfaces.

Different seals are classed as either single or double acting. A single acting seal is designed to take pressure from one side only. A double acting seal is designed to take pressure from both sides.

To suit the many different applications out there, sealing products are available in metric or imperial sizes, and can come in a wide range of standard and specialist materials.

Not all seals come ‘off the shelf’, some need to be custom made to suit the exact requirements of an existing application or for a new application that is being designed.

FPE Seals offer both, an extensive range of seals and seal kits in stock ready to order today, as well as a machined seals service, with a specialist team that can create made to order products.

If you have a sealing need or require any advice, contact our team today, we are more than happy to help.

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Question 35

What are Rotary Seals or Shaft Seals?

Accepted Answer

Rotary Seals also referred to as Shaft Seals, Oil Seals, or Lip Seals. Are designed to stop external contamination such as dirt, dust, water, and hazardous contaminants, from entering the moving parts, while retaining lubricant in the rotary applications.

The sealing effect is achieved by a garter spring which is normally used to ensure a constant force on the shaft. Rotary shaft seals are used between rotating and static machinery components.

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How Do Rotary Seals or Shaft Seals Work?

A rotary seal includes a sealing lip, a garter spring, and an external metal case. The sturdiness of the metal forms a rigidity and firm fix to the connecting components. The lip seal conducts the actual sealing function while the garter spring offers the required flexibility of movement. For vacuum applications rotary seals are designed differently and do not include a spring.

The basic design of the seal can be customised to suit specific requirements. These seals are extremely versatile and can be made of a variety of materials ranging from hard metals to plastic. The most common materials are steel, brass, silicone rubber, and EPDM.

Types Of Rotary Shaft Seals

There are different types of rotary shaft seals, each with its own specific design and materials. Some common types include:

Radial Lip Seals: These are the most common type of rotary seals. These seals are used in applications where the sealing surface is rotating relative to the housing. For low to high-speed applications, radial lip seals are designed in a wide variety of materials to best suit different fluids and temperature requirements.

V-Ring Seals: These are used for shafts that rotate in both directions. These seals are made of elastomer or rubber to prevent contamination from entering the shaft area and can handle high-speed applications.

Mechanical Seals: Mechanical seals are designed to seal against the rotating shaft using two flat surfaces. These seals can be made from a variety of materials including ceramic, carbon and metal and are typically used in high-pressure applications where a high degree of sealing is required.

Labyrinth Seals: Labyrinth seals are designed as a non-contact type of rotary seal which uses a series of grooves to create a curvy or tortuous path for the fluid or gas to flow through. These seals are effective at preventing contamination from entering the shaft area and are usually used in high-speed applications where there is a risk of fluid leakage.

Gland Packing Seals: They are typically used to seal a rotating shaft where the shaft passes through a stationary housing or casing, such as in a pump or a mixer. The packing material used in gland seals can be made of various materials such as graphite, PTFE, aramid fibre and carbon.

Choosing the Right Rotary Shaft Seal

For the proper functioning of applications, choosing the right rotary shaft seal is important. Several factors can affect the performance of rotary shaft seals, including:

Temperature: The performance and longevity of rotary shaft seal, can be affected by the operating temperature of the application, so choosing the right seal material is crucial.

Pressure: The pressure of the fluid being sealed can also affect the performance of rotary shaft seal, so it is essential that the seal chosen can withstand the pressure.

Speed: It is important to choose a seal that is designed for the appropriate speed range, so that the speed at which the shaft is rotating does not affect its performance.

Fluid type: Different fluids have different chemical properties that can affect the performance of the seal.

Benefits of Rotary Shaft Seals

Leakage Prevention: The primary function of a rotary shaft seal is to prevent leakage of fluids (such as oil, grease, or hydraulic fluid) from the housing or chamber where the shaft is rotating. By effectively sealing the gap between the rotating shaft and the stationary housing, these seals ensure that fluids stay contained within the system, reducing wastage and potential environmental hazards.

Contamination Protection: Rotary seals not only keep fluids in but also prevent external contaminants, such as dirt, dust, water, and other particles, from entering the system.

Friction Reduction: Using a well-designed rotary shaft seal can help minimise friction between the rotating shaft and the stationary housing and prevent wear on internal components, improving efficiency and reducing energy consumption.

Versatility and Reliability: Rotary seals come in various materials and designs suitable for different applications and operating conditions. They can be customised to manage a wide range of temperatures, pressures, speeds, and fluids.

Applications of Rotary Seals

Pumps: Rotary seals are used in pumps to prevent leakage of fluids such as water, oil, and chemicals.

Marine Applications: Used in applications such as propeller shafts, rudder shafts and thrusters to prevent leakage of seawater.

Food and Beverage Industry: Used in various food and beverage equipment to prevent contamination and ensure hygiene standards.

Pharmaceutical Industry: Used to prevent contamination and ensure product integrity.

If you require any further advice regarding Rotary Shaft Seals and their applications, our knowledgeable team at FPE Seals would be happy to help.

We stock, source, and supply a range of Rotary Seals. Can’t find what you’re looking for? We can also manufacture seals to your specification, in a full range of materials to meet your exact requirements.

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Question 36

The importance of mechanical seals when reducing water consumption in mining

Accepted Answer

In the industrial landscape, environmental sustainability has become a critical priority. Companies are increasingly assessing and refining their operations, processes, and systems to minimise their ecological footprint. One of the most significant areas of focus is the reduction of water consumption in mining activities, where effective pump and mixer management, along with high-quality sealing products, plays a pivotal role in conserving resources and lowering operational costs.

Water Management in Mining Operations

Water is essential in various industrial applications, especially for the hydraulic transport of solids in the mining sector. While alternative fluids like acids, kerosene, and caustics are occasionally used, water remains the primary medium due to its availability and effectiveness. However, many mines are located in regions where groundwater sources are limited, leading to increased costs for water removal and treatment. Moreover, extracting water for mining purposes can significantly impact local ecosystems and the surrounding environment.

Strategies for Reducing Water Consumption

Choosing the right selection of pumps, seals, and systems, in mining operations can significantly reduce water usage. By implementing optimal sealing solutions, companies can minimise or even eliminate the need for flushing water during the mining process.

When considering sealing solutions, it’s essential to evaluate several factors:

Equipment Condition
Downtime Costs
Product Loss
Installation Ease
Techniques for Reducing Flush Water

Effective Sealing Options

1. Packing Solutions: Packing is cost-efficient for minor leaks or product dilution. Depending on the application, three packing types can facilitate a flush-free sealing approach:

Injectables: This thermoset, heat-resistant material is composed of lubricants and chopped reinforced fibers. It is injected into the stuffing box through the flush port and requires proper application to ensure strength.

Carbon/Graphite Packing: Known for its low heat generation and high thermal conductivity, this packing option can sometimes extrude under pressure. To mitigate this, specially designed braided corners are available.

Environmental Controllers: Technologies help minimise solid contact with the packing, thus extending packing life and reducing flush water requirements.

2. Mechanical Seals: For applications where product leakage and slurry dilution are unacceptable, mechanical seals are the best option. These seals typically require no flush water, reducing treatment costs and minimising product dilution.

Single Mechanical Seals: Ideal for flush-free operations, these seals feature optimised face loading and clearances to prevent clogging.

Split Mechanical Seals: Offering water conservation and ease of assembly, split seals allow for quick installation without disassembling pumps.

Dual Mechanical Seals: In harsher slurry conditions, these seals, combined with appropriate environmental controls, can greatly minimise product dilution. Utilising a closed-loop barrier fluid system also conserves water by eliminating reliance on an external source.

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For dependable sealing products, FPE Seals offers a comprehensive range designed to meet your specific needs. To discuss your requirements or to learn more about our products, contact our expert team at +44 (0) 1325 282732

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Question 37

The Importance of High-Quality O-Rings and Seals in the Construction Industry

Accepted Answer

In the construction industry, heavy equipment is used to ensure projects are completed efficiently. It is important to maintain these equipment in optimal condition and their reliability for most construction operations.

O-rings and seals help in keeping hydraulic systems operating smoothly. Selecting the right seals for your equipment, considering durability, material composition, and application, is essential for maximising performance and longevity.

In this article, we will explore the importance of choosing the right construction seals and O-rings for hydraulic equipment and discuss their key benefits for the construction industry.

Benefits of Seals and O-rings in the Construction Industry

O-rings and seals provide benefits that support the efficient operation of hydraulic equipment in construction:

Prevents Leakage: O-rings and seals help prevent fluid leakage, which reduces the risk of equipment failure and costly downtime.
Protects Against Contaminants: They act as barriers, preventing dirt, debris, and other contaminants from entering the system and causing internal damage.
Handles Various Pressure Levels: O-rings can be designed to function in both high- and low-pressure systems, making them versatile for different applications.
Highly Durable: Construction seals and O-rings are known for their exceptional durability, which means they can withstand the rigors of daily use in harsh environments.
Low Maintenance: These components require minimal maintenance, allowing construction projects to progress without frequent interruptions.
Cost-Effective: O-rings and seals are affordable, making them a cost-effective solution for enhancing the reliability of construction equipment.
Prevents Blowouts: In applications like oil plants, seals and O-rings can help reduce the occurrence of blowouts, which can be hazardous and expensive to manage.
Resistant to Wear and Tear: With resistance to chemicals, water, and extreme conditions, O-rings and seals provide long-lasting protection for hydraulic systems.
Easy Replacement: When repairs or maintenance are necessary, seals and O-rings can be quickly replaced, reducing downtime and keeping projects on schedule.

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The Risks of Seal Failure in Construction

Using incompatible or low-quality seals can result in failures, leading to equipment damage and project delays. It's essential to choose the right type of seal for your specific equipment and operating conditions to avoid these risks.

Here are some of the key challenges that construction seals and O-rings must withstand:

Extreme Temperatures: Construction equipment often operates in environments with extreme heat or cold. Seals must be able to maintain their integrity under prolonged exposure to high temperatures.

Exposure to Harsh Chemicals: Hydraulic systems frequently come into contact with chemicals that can erode materials. Choosing a seal made from chemically resistant materials is critical for long-term performance.

Dirt and Debris: Construction sites are filled with dirt, dust, and debris, which can compromise the functionality of hydraulic systems. Seals need to be tough enough to protect against these external contaminants.

FPE Seals for Reliable O-Rings and Seals

If you're looking for high-quality O-rings and construction seals, FPE Seals has the expertise and products you need. With years of experience in delivering sealing solutions to a wide range of industries, we offer tailored products designed to meet the specific demands of your equipment.

Whether you require hydraulic cylinders, seals, or O-rings for industrial applications, our team is ready to assist you. Browse our selection of seals online or contact us today for personalized support and guidance

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Question 38

How to Check if Hydraulic Cylinder is Leaking Internally

Accepted Answer

Internal leaks in hydraulic cylinders can be caused when hydraulic fluid unintentionally flows from one side of the piston to the other. This happens due to worn-out seals, cracks, or issues with the piston. In a hydraulic system, as fluid is restricted to its designated areas, it helps to maintain proper pressure and ensures smooth operation. But when an internal leak occurs the fluid escapes, resulting in pressure loss and a decrease in overall system efficiency.

The Impact of Internal Leaks

Internal leaks can affect your machinery in various ways, from minor to more serious safety concerns. When fluid leaks inside the cylinder, it reduces the amount of force generated which slows down the cylinder's ability to extend or retract causing additional wear on equipment, increasing costly repairs and downtime. From a safety point, unpredictable movements caused by internal leaks can also present hazards for operators working with or near the equipment.

How to Spot Internal Leakage

Physical Signs: You might notice oil stains or puddles forming underneath the equipment, which can signal that fluid is leaking through internal pathways. You may also hear unusual noises, like hissing or gurgling, which could indicate fluid is moving where it shouldn't be. Additionally, signs of wear, such as damage to the cylinder, piston rod, or seals, can point to an ongoing leak.

Performance: Internal leaks often affect how well your machinery performs. If the hydraulic cylinder is extending or retracting more slowly than normal, it may be a sign that fluid is leaking inside. Erratic or jerky movements are another indicator, as leaks can cause uneven fluid distribution. You might also notice the overall system feels less efficient, needing more power to do the same tasks.

The Importance of Regular Maintenance

By checking your hydraulic cylinders regularly, you can spot signs of wear or small leaks early on. This not only helps maintain your system’s performance and safety but also extends the life of the equipment.

Repair Solutions

Seal Replacement: Worn-out seals are a common cause of internal leaks. Replacing them can often resolve the issue quickly.
Cylinder Repair or Replacement: If the cylinder itself is worn or damaged, replacing it may be necessary to stop the leak.
Piston Rod Repair: A bent or damaged piston rod can also cause leakage. Repairing or replacing the rod may be required in such cases.

Addressing internal leaks in hydraulic cylinders is crucial to keeping your systems running efficiently and safely. By learning to recognise the signs of leakage, performing regular inspections, and using effective repair strategies, you can ensure that your hydraulic equipment continues to function reliably over time.

Replacing hydraulic cylinder seals and parts

At FPE Seals, we’re here to help you maintain the highest standards of quality and safety in your operations. Can't find what you're looking for? Our expert teams can source hard-to-find items or custom-manufacture a full range of parts, including wiper seals and piston rings in metric or imperial to meet every customers' needs.

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Question 39

Why Quality Piston Seals Matter in Heavy-Duty  Applications

Accepted Answer

Piston seals are used to prevent hydraulic fluid or air from leaking when the piston moves within a cylinder. This makes piston seals important hydraulic cylinder seals in heavy-duty machinery. These seals are widely used in machinery like earth-moving equipment, industrial manufacturing machines, and automated systems to enhance the performance of hydraulic and pneumatic systems. The primary function of these seals is to maintain pressure within the system, which is important for the equipment to operate effectively.

In hydraulic systems, to perform tasks such as lifting, pushing, or rotating loads, the fluid pressure is generated by the pump and then transmitted through the piston. Piston seals ensure this pressure is maintained by preventing any fluid leakage from flowing past the piston.

Why High-Quality Piston Seals Matter?

Using low-quality seals can lead to issues that can cause system failures. Here’s why choosing high-quality piston seals is so important for heavy-duty applications:

Preventing Leaks and Maintaining Efficiency: High-quality seals are designed to resist the pressures found in heavy-duty machinery, ensuring that the system remains leak-free and operates at maximum efficiency.

Ensuring Durability and Long Service Life: These seals are made from durable materials that can withstand the rigours of heavy-duty use, offering longer service life and greater reliability. This not only reduces the need for frequent maintenance but also extends the overall lifespan of the equipment.

Enhancing Safety: A failure in the piston seal can lead to unexpected equipment movements, loss of control, or even total system failure. Such incidents can cause serious injuries or environmental hazards, particularly if the system handles hazardous fluids. High-quality piston seals are engineered to meet safety standards, reducing the risk of such failures and ensuring the safe operation of machinery.

Customisation and Compatibility for Specific Applications: Not all piston seals are created equal, and the requirements for heavy-duty applications can vary greatly depending on the machinery and operating conditions. FPE Seals offer a range of seals tailored to different applications, providing options for various materials, sizes, and designs, ensures that the seal is compatible with the specific requirements of the machinery, further enhancing its performance and reliability.

If you require any further advice regarding seals and their applications, the team of experts at FPE Seals can help you source what you need.

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Question 40

What is the difference between a single acting and a double-acting cylinder?

Accepted Answer

Hydraulic cylinders are used on various types of machinery and equipment, but there are two main types: single-acting and double-acting cylinders. Each type has its own distinct designs and operational benefits. In this blog, we will discuss how these cylinders work and help you determine which one is right for your needs.

How Does a Single-Acting Cylinder Work?

Single-acting cylinders operate with hydraulic fluid entering through a single port to push the piston in one direction, typically outwards. This extension is the stroke of the cylinder combined with the size and pressure, generating the desired force.

But what about retraction? A single-acting cylinder relies on an external force, such as a load, spring, compressed air, or even gravity, to pull the piston back to its original position. This makes them well suited for applications where force is only needed in one direction.

Advantages of Single-Acting Cylinders:

Their design is less complex, with lower costs and easier maintenance.
With fewer components, single-acting cylinders are smaller and lighter, ideal for space constrained applications.

Disadvantages of Single-Acting Cylinders:

Single-acting cylinders offer less control over the retraction speed and force.
Due to unidirectional control, single-acting cylinders are not suitable for tasks requiring both pushing and pulling.
Prone to ingress of moisture causing rust in the bore

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How Does a Double-Acting Cylinder Work?

Double-acting cylinders have two ports, one on each side of the piston. By alerting the directing of hydraulic fluid into either port, they provide both extension and retraction with precise control. Fluid entering one port pushes the piston out, while fluid entering the other port retracts it.

Advantages of Double-Acting Cylinders:

The ability to control the flow of fluid in both directions allows for precise control over speed and force during both extension and retraction.
Double-acting cylinders are suitable for various applications that require both pushing and pulling actions.

Disadvantages of Double-Acting Cylinders:

Their design is more complicated, leading to higher costs and potentially more complex maintenance.
With the additional port and internal mechanisms, double-acting cylinders can be larger and heavier than single-acting cylinders.

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Choosing the right cylinder for your application depends on some key factors:

If force is needed in only one direction, a single-acting cylinder might be sufficient. However, for applications requiring both pushing and pulling, a double-acting cylinder is necessary.
If precise control over speed and force in both directions is crucial, a double-acting cylinder is the better choice. However, if a basic extension is sufficient, a single-acting cylinder can save you money.

FPE Seals stocks and manufactures a full range of sealing solutions and metal parts for hydraulic cylinders. From piston seals, wiper seals, O-rings, and complete cylinders.

Order online today or contact our knowledgeable team here at FPE Seals, who will discuss your requirements based on your application, and help you find the right seal for the job.

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Question 41

5 Factors to Consider When Designing FDA Seals for Food Contact

Accepted Answer

Designing FDA seals for food contact is a critical task that involves ensuring regulatory compliance, selecting the right materials, and maintaining consumer safety. These seals are essential in food packaging, storage, and transport, ensuring that food remains safe and uncontaminated.

Here are five key factors to keep in mind:

1. Regulatory Compliance

When creating FDA seals for food contact, the first and foremost consideration is regulatory compliance. The Food and Drug Administration (FDA) has strict guidelines for materials that come into contact with food. These regulations ensure that the materials used are safe and do not release harmful substances into the food.

Compliance involves thorough testing and certification. The materials must meet specific standards for chemical composition, durability, and resistance to various conditions.

2. Material Selection

The material must comply with FDA regulations and possess the properties necessary to maintain its integrity under various conditions. Common materials include silicone, rubber, and certain plastics, each with its benefits.

Silicone: Known for its flexibility and resistance to extreme temperatures, silicone is a popular choice for seals used in both hot and cold food applications.

Rubber: Valued for its durability and flexibility, rubber suits various sealing applications but must be carefully selected to avoid substances that could degrade upon contact with food.

Plastics: Various plastics, like polyethylene and polypropylene, are used for their versatility and cost-effectiveness. However, they must be selected to ensure they do not release harmful chemicals.

3. Temperature Resistance

Food processing, packaging, and storage often involve a wide range of temperatures. Therefore, FDA seals must maintain their integrity across these temperatures. For instance, seals in freezer applications must remain flexible at sub-zero temperatures, while those used in cooking or pasteurisation must withstand high heat.

4. Chemical Compatibility

Food products contain various substances, including acids, oils, and other chemicals, which might react with the seal material. Ensuring chemical compatibility is crucial to prevent contamination and degradation of the seal.

For example, acidic foods like tomatoes or citrus fruits can cause certain materials to deteriorate, compromising the seal’s effectiveness and leading to contamination. Similarly, fatty foods can interact with rubber or plastic, causing material breakdown. Designers must evaluate the chemical properties of the food the seal will contact and choose materials that resist these reactions.

5. Mechanical Properties

The mechanical properties of the seal, such as flexibility, elasticity, and durability, significantly impact its performance. A seal must provide an effective barrier while withstanding mechanical stresses during packaging, transport, and use.

Flexibility and Elasticity: The seal must conform to the surfaces it contacts to prevent leaks and contamination. Materials that are too rigid might not form an adequate seal, while those that are too soft might wear out quickly.

Durability: The seal must endure repeated use and mechanical stress without losing its effectiveness. This includes maintaining its properties over time despite exposure to various environmental factors.

Proper testing during the design phase can help identify potential weaknesses in the seal’s mechanical properties. This might include stress tests, fatigue tests, and real-world simulations to ensure the seal performs as expected under all conditions.

Designing FDA seals for food contact is a multifaceted task requiring careful consideration of regulatory compliance, material selection, temperature resistance, chemical compatibility, and mechanical properties. Each factor plays a crucial role in ensuring the safety, effectiveness, and longevity of the seal.

Our team are more than experienced in providing sealing solutions for a wide variety of equipment and applications used to process and produce food and beverages, having worked closely with our customers in this industry for many years.

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Question 42

Common cause of seal failure in food processing systems and how to prevent them.

Accepted Answer

Seal failure in food processing systems poses significant challenges to manufacturers, compromising both operational efficiency and product safety. Seals play an important role in maintaining the integrity of equipment, preventing contamination, and preserving the quality of processed foods. It's important for food processing facilities to understand the common reasons behind seal failures and implement preventive measures to ensure seamless operations and maintain industry standards.

Common Causes of Seal Failure & How to Prevent Them.

Several factors contribute to seal failure in food processing systems:

Compatibility: All seal materials need to be compatible with the properties of the processed food and the fluids used in cleaning processes. If materials are incompatible, they can degrade, resulting in seal breakdown, leaks, or contamination. It's crucial to regularly assess material compatibility with the specific operating conditions and chemical exposure of your processing environment to enhance durability and longevity.

Sanitization: Incorrect or insufficient cleaning and sanitation practices can contribute to seal degradation or contamination. Developing a strict cleaning procedure and ensuring they are consistently followed can help prolong the lifespan of seals.

Over-tightening: Applying pressure during installation can cause seals to deform or fail prematurely. Proper training should be provided to staff to ensure they adhere to recommended specifications and techniques during seal installation, avoiding over-tightening.

Under-tightening: Conversely, inadequate tightening may result in ineffective sealing, leading to leaks. Implement quality control measures to verify that seal applications are appropriately tightened during installation.

Temperature Extremes: Food processing often involves extreme temperature variations. It's essential to use seals that are rated for the specific temperature ranges encountered and select the appropriate seal material accordingly. Heat-resistant or cold-resistant seals should be employed where necessary.

Hygienic Issues: Seals help in preserving the integrity of food products. Cross-contamination can occur if seals fail. Following to HACCP (Hazard Analysis and Critical Control Points) protocols helps mitigate these risks.

Maintenance Schedule: Develop a comprehensive maintenance schedule that includes regular inspections, seal replacement, and staff training. Regular maintenance activities help in the early detection and address seal issues before they escalate into significant problems.

By adopting these preventive measures, food processing manufacturers can safeguard their equipment against seal failure, uphold product quality standards, and maintain regulatory compliance.

FPE Seals are more than experienced in providing sealing solutions for a wide variety of equipment and applications used to process and produce food and beverages.

Order online today or get in touch with our knowledgeable team here at FPE Seals, who will discuss your requirements based on your application, and help you find the right seal for the job.

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Question 43

Why do mechanical seals fail?

Accepted Answer

A mechanical seal is a seal that prevents the leakage of fluid or gases between two rotating or moving parts in the machinery, commonly used in pumps, compressors, and other rotating machinery.

The primary cause of pump downtime often stems from mechanical seal failures. To mitigate this issue, selecting the appropriate seal tailored for the specific function required is important.

Mechanical Seal failure often occurs, but why?

Here are the most common causes for a mechanical seal failing within a process.

Running the pump or machine dry: When a pump is operated without fluid, exposes internal components to high levels of friction and heat, leading to rapid failure. To avoid this, it is crucial to ensure the pump is filled with fluid before operation. If a seal has been dry run, the face of it will be white. Using an AMP sensor can help detect excessive AMPs, preventing further damage by stopping pump operation in time.

Excessive vibration: Vibrations in pumps can be caused by improper alignment, pump imbalance, or operation beyond the best efficiency point (BEP), damaging the machine and shortening the lifespan of the seal.

Hammering couplings: Machines containing components like pistons that have an intense hammering action can induce substantial vibration and movement, posing challenges for both the machine and the seals.

Incorrect Fitting: When a seal is installed, it is designed to have lateral and vertical movement with the shaft. Incorrect installation can cause excess play, damaging forces to the seal. The seal springs can snap and face wear due to restricted movement.

Worn Shaft or Wear: When a seal is replaced certain elastomers such as Viton can increase shaft wear. If the shaft has a smaller OD reduced by friction over the years, then the seal will not fit tightly enabling fluid to leak.

Contamination: Due to inadequate filtration, improper maintenance, or improper handling of the equipment the abrasive particles, dirt, or debris in the sealing environment can accelerate wear on the seal faces causing premature failure.

Excessive heat or temperature fluctuations: Operating the mechanical seal beyond its recommended temperature limits or subjecting it to rapid temperature changes can cause thermal stress, distortion, or thermal cycling that can lead to seal damage or failure.

Fluid incompatibility: Every material has its weaknesses. Exposure to fluids that are incompatible with the seal materials can cause internal parts such as rubber seals, gaskets, impellers, pump casings and diffusers to crack, swell, contract, or deteriorate.

Human error: Simple mistakes by operators can contribute to seal failures for example incorrectly starting the machine, leading to motor tripping and shaft twisting, can result in internal parts movement coming into contact, causing seal failure, and reducing the life of bearings.

To avoid or reduce mechanical seal damage, it is important to follow proper installation procedures, conduct regular maintenance, ensure proper lubrication and fluid filtration, monitor operating conditions, and utilise compatible seal materials for specific applications.

Browse our range of Mechanical Seals on our webstore or contact one of our knowledgeable teams today who are happy to advise on finding you exactly what you need.

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Question 44

What are the benefits of mechanical seals?

Accepted Answer

A mechanical seal is designed to seal the gap between a rotating shaft and a stationary housing, or occasionally, where the housing rotates around the shaft, preventing fluid leakage within a vessel such as pumps, mixers, etc., ensuring efficient and reliable operation of the equipment.

Types of Mechanical Seals

Mechanical Seals provides various choices to fulfill different requirements, making it a great option for efficiently maintaining and repairing equipment.

Conical 'O'-Ring Mounted Mechanical Seals: These seals are available in both DIN and standard dimensions, offering reliable performance and preventing leakage, making them ideal for use in pumps, compressors, mixers, and agitators. Their conical shape allows easy installation and alignment. In demanding operational environments, these seals ensure durability and efficiency, contributing to equipment productivity.

Parallel 'O'-Ring Mounted Mechanical Seal: These seals are available in both imperial and metric sizes, provide reliable sealing performance in challenging environments, making them suitable for industries such as marine, paper, refrigeration, wastewater, and textiles. Their robust and flexible shape ensures high performance, leakage prevention, and system integrity.

Water Pump Mechanical Seals: Used in significant quantities for the production of pumps used in pools, showers, irrigation, and heating systems, these seals offer outstanding sealing performance designed specifically for water-related applications. Their cost-effectiveness and reliable sealing capabilities make them a popular option in diverse industries associated with water.

Elastomeric Bellows Mechanical Seals: With its non-clogging design, these seals are ideal for various applications and exhibit excellent performance when dealing with media that includes solid particles. They provide reliable sealing performance in diverse operating conditions.

Multiple Spring Mechanical Seals: Both balanced and unbalanced designs offer an optimal solution in corrosive environments. With a standard stainless-steel construction, these seals guarantee durability and resistance to corrosion, providing reliable sealing performance in challenging conditions, and making them well-suited for demanding industrial applications.

Diaphragm Mechanical Seals: These single spring seals with an elastomer membrane are tailored for demanding applications. Covering a range of sizes to fit standard shaft and housing dimensions, these seals ensure compatibility with various equipment. Offering reliable sealing performance in challenging operating conditions, is a durable choice with flexible sizing options for a wide range of industrial applications.

Wave Spring Mechanical Seals: The compact and bi-directional wave spring mechanical seals are the right choice for applications with limited space, such as rotating lobe pumps. Their hygienic properties are well-suited for pumps used in industries such as food, dairy, brewery, and pharmaceutical. They provide reliable sealing performance and are preferred for critical applications with industries demanding high cleanliness standards.

Cartridge Mechanical Seals: Designed with multiple springs and an O-Ring mounted cartridge, available with various bolt combinations and flush ports ensuring convenient installation and reliable sealing performance. The cartridge design not only simplifies maintenance but also facilitates quick and efficient replacements, minimising downtime.

Stationary Mechanical Seals: Designed to provide a reliable and stationary sealing solution between two stationary surfaces, such as pump casings or gearbox housings. These seals are used in various industrial applications ensuring efficiency, safety, and longevity in equipment across industries like manufacturing, oil and gas, chemical processing, and more. These seals are available in different designs and materials to meet specific requirements and operating conditions.

Benefits of Mechanical seals

Safety: Provides a high level of safety by effectively preventing leaks and spills. Their ability to withstand high-pressure and high-temperature conditions ensures the containment of fluids within the equipment, minimising the chances of accidents, environmental harm, and equipment failures.

Reduced Downtime: Designed to last longer compared to traditional packing seals, which helps in reducing equipment downtime. With less need for maintenance and replacement can save businesses time and money in the long term.

Efficiency: Enhances the overall efficiency of the equipment’s operation by using less energy to overcome the resistance caused by friction, allowing equipment to operate at a higher capacity. This can result in increased productivity and lower operating costs.

Flexibility: Used in a wide range of applications, from pumps and compressors to mixers and agitators. Available in various materials, sizes, and designs to meet specific industry requirements, making them a versatile choice for numerous industrial applications.

Environmental Friendliness: As they reduce the impact of leaks and spills that can harm the environment & require less maintenance, which reduces the use of resources and waste production, makes them an environmentally friendly choice.

Choosing the Right Mechanical Seal

Fluid Type and Properties: The choice of mechanical seal depends on the fluid being transferred and its characteristics, including temperature, viscosity, and corrosiveness. To ensure compatibility with the fluid and prevent any potential leaks, it may be necessary to use different materials and designs.

Operating Conditions: Select a seal that can withstand the operating conditions of the equipment such as pressure, temperature, and speed, to which it will be exposed to. The right seal design and material must be chosen to ensure optimal performance.

Equipment Type and Design: Consider the design aspects, such as shaft diameter, housing, and mounting, to ensure seal compatibility.

Industry Standards and Regulations: Some industries have specific requirements for seals, such as food-grade materials for use in the food industry, or compliance with certain safety standards.

Cost: It is important to ensure the best value for your investment by considering the long-term costs, such as maintenance and replacement.

We offer replacement seals for the maintenance and repair of pumps, compressors, and rotary equipment used across all industries including Construction, Food and beverage, Water Processing, Chemical, Pharmaceutical, Oil and gas, Marine, Refrigeration, Pool & Leisure, Mining, Semiconductor, and Environmental.

Get in touch with our knowledgeable team here at FPE Seals, who will discuss your requirements based on your application, and help you find the right seal for the job.

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Question 45

What types of seals are used in the marine industry?

Accepted Answer

Onshore and offshore, the marine industry works within vast and challenging environments, relying heavily on precision engineering to ensure the safety, efficiency, and longevity of its equipment.

Seals are used effectively in maintaining the integrity of various marine applications to prevent leaks and protect operating systems for optimal performance.

Types of seals used in the marine industry:

Mechanical Seals: Used to prevent fluid leakage ensuring that oil, water, or chemicals don't infiltrate the machinery and cause damage to internal components, commonly found in pumps and propeller shafts, where maintaining a watertight seal is critical.

Gaskets: Commonly used in flanged joints, providing a reliable barrier against fluids and gases. Gaskets come in various materials including rubber, cork, and metal, depending on the required properties for the application. In marine engines and boilers, gaskets are utilised to prevent the escape of steam and other fluids, contributing to the overall safety and efficiency of the equipment.

O-Rings: Commonly used in the marine industry due to their versatility and reliability. These circular elastomeric seals create a secure barrier against fluid or gas leakage in applications. O-rings are typically placed in grooves or recesses and are compressed between two mating surfaces.

Hydraulic Seals: Designed specifically for use in hydraulic systems. These seals are vital in marine applications, particularly in hydraulic cylinders used for steering systems, hatch covers, and other moving parts, maintaining the stability and flexibility of the application.

Oil Seals: Also known as shaft seals, designed to prevent the leakage of lubricating oil from rotary shafts. These seals are commonly used in engines, gearboxes, and propulsion systems where rotating shafts are prevalent. Oil seals help in extending the life of machinery by preventing the loss of essential lubricants.

Washers: Thin, flat rings used to distribute loads and prevent leakage between connected components. Washers are employed in various applications, such as flanged connections, valves, and pumps. They help distribute the load evenly and create a reliable seal, contributing to the overall integrity of the application. Available in different materials, including rubber, metal, and fibre, depending on the specific requirements of the application.

Retaining Rings: Also known as circlips or snap rings, are used to secure components on shafts or in bores. In marine applications, retaining rings are utilised in propeller shafts, bearings, and other rotating components to prevent axial movement and ensure the stability of essential parts.

Back-Up Rings: Are used in conjunction with O-rings and other seals to provide additional support and prevent extrusion under high pressures. In the marine industry, where hydraulic and pneumatic systems operate under challenging conditions, back-up rings are employed to enhance the durability and performance of seals.

FPE Seals stocks and manufactures a full range of sealing solutions and hydraulic cylinder products that best serve operations related to the offshore and onshore business of ships, boats, yachts, subsea equipment, maritime infrastructure, and technology, whether that be for naval, commercial or leisure.

Order online today or get in touch with our knowledgeable team here at FPE Seals, who will discuss your requirements based on your application, and help you find the right seal for the job.

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Question 46

What Safety Precautions Should You Take When Working with Hydraulic Cylinders?

Accepted Answer

Hydraulic cylinders are used for various tasks that involve pulling, lifting, bending, or holding. With so many ways they can be used, comes a lot that can go wrong.

To avoid the risk of harm while using such cylinders, there are many safety precautions you need to consider.

80% Rule

When it comes to setting up an optimal hydraulic system, your primary concern should always revolve around safety, both for yourself and others involved. When using hydraulic cylinders, it is advisable to limit usage to only 80% of the load and stroke ratings, as most loads are not lifted on their true centre, which introduces an external side load force and increases the risk of load instability.

Provide Support

For a cylinder to operate safely and efficiently, it necessitates to operate on a firm and level base. This implies that the cylinder's operation should be placed flat on the ground, i.e. stabilizer legs or outrigger on a crane. It's crucial to ensure that the surface beneath the cylinder is free from any debris. If you have any doubts about the stability of the surface, it's recommended to employ a base plate for added stability.

Pressure Gauge

A pressure gauge is a vital component of any hydraulic system. Using a pressure gauge helps to monitor the force applied on the cylinder within the reasonable margin of safety. This is not only important for safety, but it is also necessary for maintaining the quality of your equipment.

Cylinder Condition

Before using a hydraulic ram cylinder, it's crucial to inspect it for signs of damage. If any damage is detected, the cylinder may not function properly and should not be used. There are various reasons why a cylinder might not work correctly which could cause system failure that leads to safety hazards and injury.

Reasons why a cylinder may not function properly:

A cylinder will not extend if the coupler is not fully tightened, the pump is worn, the oil level is too low, the pump is malfunctioning, or the pump pressure relief valve is set too low. Additionally, if the cylinder is already at full stroke, it will not extend further.
If a cylinder only extends partially, this may be due to insufficient oil capacity or an external obstruction or bent rod.
When a cylinder does not extend smoothly, it could be due to air in the system.
If a cylinder extends but cannot hold the load, it may be due to leaking seals, a malfunctioning pump or valve, or a leaking connection.
Cylinder leakage may occur due to cylinder or seal damage or a loose connecter.
Cylinders may be slow to retract or not retract at all, this can be caused by a loose piston seal carrier or damaged piston seals, or worn hydraulic pump.

Replacing hydraulic cylinder seals and parts

FPE Seals provide replacement parts for all hydraulic cylinders and specialise in providing sealing solutions for aftermarket and OEM applications. View what is on offer on our website or contact one of our knowledgeable team today who are happy to advise on finding you exactly what you need.

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Question 47

Measure a Hydraulic Cylinder

Accepted Answer

When it comes to replacing hydraulic cylinders, accurate measurement and sizing are crucial to prevent issues that may arise during the replacement process. In this guide, we will explore how to measure a hydraulic cylinder using simple tools.

Key Measurements for Hydraulic Cylinders

To measure hydraulic cylinder components accurately, You will need to focus on key measurements and use tools such as a tape measure and vernier callipers.

Primary Components for Hydraulic Cylinder Measurement

Retracted hydraulic cylinder length: When the cylinder is full retracted, (Closed Centres) measure from the centre of the rod pin to centre of the cylinder pin.
Extended hydraulic cylinder length: When the cylinder is fully extended, (Open Centres) measure from the centre of the rod pin to centre of the cylinder pin.
Stroke length: Measure the extended length of the hydraulic cylinder minus the retracted length.
Bore diameter: Measure the outside diameter of the cylinder and subtract the wall thickness of the tubing. Standard bore sizes range from 25mm to 125mm bore diameters.
Rod diameter: This measurement is mainly done with callipers.
Cylinder pin size
Rod mount pin size
Base and rod mount dimensions
Determine port size and style.

It is important to understand which type of hydraulic cylinder you are replacing, whether it is Single acting, Double acting or Displacement, to ensure an accurate cylinder replacement.

Check Out Our Hydraulic Cylinder Measurement Guide

Watch our video which demonstrates how to measure a Hydraulic Cylinder

FPE Seals offers a comprehensive range of replacement hydraulic cylinders kits, metal parts, seals, and accessory parts. For expert guidance with your cylinder design or choosing the replacement parts you need, contact our knowledgeable team today.

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Question 48

What are hydraulic hand pumps used for?

Accepted Answer

Hydraulic hand pumps are commonly used to load and test machinery components, as well as in handling machinery for raising and lowering heavy objects. By operating the hand lever, users can create pressure, enabling the lifting, pushing, or bending of heavy objects with ease.

Types of Hydraulic Handpumps

There are two types of hydraulic hand pumps:

Single Acting Hand Pumps	Double Acting Hand Pumps
Supplies a single flow in a dual-action hand pump.	Supplies a single flow in a dual action hand pump, fitted with an additional lever to divert the flow.
Simple in design and easier to maintain.	More complicated to maintain and repair
Commonly used in hydraulic jacks.	Used in a wider range of applications, including aircraft hydraulic systems.
More strokes are needed to generate the pressure and movement	Less strokes are needed to generate the pressure compared to single acting hand pump
Slower in operation.	Preferred for speed and efficiency

Applications of Hydraulic Handpumps

Hydraulic Systems Testing: Hydraulic hand pumps are frequently employed to test and troubleshoot hydraulic systems. They enable manual pressurisation of the system, facilitating leak detection and evaluation of overall system performance.

Hydraulic Jacks: Used to operate hydraulic jacks, which are widely employed for lifting heavy loads or vehicles. By operating the hand pump, hydraulic pressure is generated, causing the jack to extend and elevate the load.

Hydraulic Tools: Provide the necessary pressure to operate hydraulic tools, including crimpers, cutters, and presses. These tools find applications in sectors such as construction, automotive, and manufacturing, where manual operation is required.

Agricultural Machinery: Powers hydraulic systems in agricultural machinery such as tractors & loaders. They enable manual operation of hydraulic functions, including lifting and tilting attachments or adjusting hydraulic system pressure.

Laboratory and Testing Equipment: Used in laboratories and testing facilities for various purposes, such as calibrating pressure gauges, testing pressure sensors, and conducting experiments requiring controlled hydraulic pressure.

Marine and Offshore Applications: Utilised in marine and offshore environments for tasks such as operating hydraulic steering systems, lifting heavy equipment, or controlling hydraulic winches and cranes.

FPE Seals offers a range of hydraulic handpumps including single acting hand pumps, double acting handpumps & stand-alone handpumps with various capacities. If you can't find what you're looking for, feel free to get in touch with our knowledgeable team for further advice and information about our products, including a full range of hydraulic ram components.

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Question 49

How do Swivel Joints Work?

Accepted Answer

The Swivel Joint, also known as the Rotary Coupling, Rotary Union, Swivel Union, Rotorseal, and Rotary Joint, plays a key role in controlling hydraulic circuits on an excavator.

Excavators use many hydraulic moving parts, to help manoeuvre the mechanical arm, reposition the bucket, adjust the digging angle, and control the tracks or wheels.

This requires different hydraulic circuits,

Upper: Mechanical arm elements
Lower: Tracks or wheels

The swivel connects the two together through a central shaft, to avoid a mass of twisted, tangled, or torn parts. Holes bored into the shaft allows fluid to flow through the swivel to its targeted cylinder, and as the centre shaft moves independently without restricting fluid flow, both upper and lower elements can move in different directions.

Typical design of a Swivel Joint

All swivels are not the same and will vary based on the number of mechanical elements on the upper moving section. Swivel joints can require anything from 3 to 10 seals to function correctly.

FPE Seals offer a wide range of competitively priced, OEM quality replacement seal kits for the repair and maintenance of swivel joints on excavators. Find out more here or contact the team to discuss your requirements.

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