How to Spot Problems in Hydraulic Systems used in Coal Handling Preparation Plant

Hydraulic systems perform a critical role in the operation of coal handling and preparation plants across Australia. From powering critical infrastructure such as breaker feeders and loading systems for smooth and reliable operation, hydraulic components are central to productivity. But in the demanding environment of coal processing, where every minute of downtime equals lost revenue, effective hydraulic maintenance becomes not just an option -but a necessity.

By focusing on proactive hydraulic system care – including proper component selection, advanced filtration systems, and lubrication tailored to harsh environments – operators can significantly enhance equipment performance, reduce maintenance costs, and improve workplace safety.

Why Hydraulic System Maintenance Matters in Coal Plants

Coal preparation plants operate under demanding conditions, where dust, heat, and high operational loads are continual challenges that components must withstand. Hydraulic systems, if not properly maintained, are vulnerable to contamination, overheating, and mechanical failures – all of which can bring operations to a standstill.

Key benefits of proactive hydraulic maintenance include:

• Minimised Downtime: Prevent unexpected system and component failures through regular inspections and servicing.
• Improved Safety: Well-maintained systems reduce equipment malfunctions, reducing the potential of injury to personnel and environmental impacts.
• Extended Equipment Life: Proper lubrication and filtration help prevent wear, saving on replacement costs.
• Optimised Performance: A clean, efficient hydraulic system operates more efficiently and with better precision.

Common Hydraulic System Challenges in Coal Handling Plants

In mining environments, such as in coal handling and preparation facilities, numerous risks exist to hydraulic systems. Recognising and addressing the common issues early can prevent serious disruptions.

1. Contamination

Coal dust and airborne particles easily infiltrate hydraulic systems, especially in open or poorly sealed environments. Once inside, these contaminants degrade hydraulic fluid, cause abrasive wear on components, and, as a result, significantly reduce system life.

Solution:
Invest in high quality filters and hydraulic components that contain fit-for-purpose seals. Regular fluid testing helps monitor for signs of contamination before they get out of control.

2. Improper System Adjustments

Improper system maintenance can lead to deeper issues over the operating life of the hydraulic system. Tweaks or temporary fixes may cover problems that are due to irregular or poor maintenance. This could include inadequate filter replacement cycles, or poor system maintenance practices such as oil overheating not being monitored or attended to in a timely fashion and may impeded correct diagnosis.

Solution:
Every hydraulic system should have a maintenance schedule, supplied by the OEM, that should be adhered to by the system operator. By following the recommended schedule, the operating life of the system will be extended.

3. Cooling Failures

Hydraulic fluid temperatures must remain within an optimal range, dictated by the OEM. Overheating can degrade fluid quality, damage internal parts, and reduce system responsiveness.

Solution:
Implement reliable cooling systems, such as air-blast coolers,  monitor fluid temperatures with sensors, and ensure correct responses to overheating scenarios (warning/shut-down) to prevent further damage. 

The Importance of Component Selection in Harsh Environments

In Australian coal preparation plants, selecting the right hydraulic components is critical for reliable operation. Choosing robust, high-quality parts designed for imining use pays off in operational uptime and reduced maintenance.

What to consider when selecting components:

• Adequate Rating Under Load: Hoses, seals, and cylinders should be rated for continuous pressure operation, as per system requirements.
• Environmental Resistance: Components must withstand high temperatures, dust exposure, and corrosive conditions.
• Manufacturer Support: Choose reputable brands with a track record of reliability and support for mining applications, such as Parker, Hydac and Sun Hydraulics.

Using premium components from the outset reduces the frequency of breakdowns and ensures a longer system lifecycle, especially in 24/7 operations common in coal processing.

Filtration: The First Line of Defence

Filtration is one of the most critical aspects of hydraulic system maintenance. Effective filtration prevents contaminants from circulating through the system, protecting sensitive components from wear and ensuring fluid cleanliness.

Best practices for hydraulic filtration:

• Use high-efficiency, high quality filters: Select filters rated for mining and heavy-duty applications.
• Monitor filter Condition: Use filters with monitoring to ensure they are replaced on a regular basis and as required. As a minimum, filters should be replaced as per the maintenance schedule. Don’t wait for performance to drop!
• Test Fluids Periodically: Identify contamination early through fluid analysis, preventing unseen damage.

Inadequate filtration leads to component damage, overheating, and ultimately system failure. A small investment in quality filtration yields long-term operational stability.

Lubrication in Dusty Environments

Fixed plant equipment in coal preparation facilities operates in dusty, abrasive environments that accelerate component wear. Lubrication is essential – but must be tailored to these conditions.

Effective lubrication strategies include:

• Use fit-for-purpose lubricants: Choose products formulated for the needs of the system, as per the OEM specifications. 
• Seal vulnerable areas: Covers and seals protect lubrication points from external contaminants.
• Establish regular lubrication Intervals: Prevent friction and surface degradation with a consistent maintenance routine.

A well-lubricated system reduces friction, limits overheating, and extends equipment service intervals – essential in remote or difficult-to-access locations.

Keeping Your Hydraulic Systems in Peak Condition

Maximising efficiency in coal handling operations requires a structured approach to hydraulic maintenance. From choosing the right parts to implementing thorough filtration and lubrication protocols, each element contributes to reliable performance.

To maintain high-performance hydraulic systems:

• Schedule regular inspections and servicing.
• Choose components suited for mining environments.
• Implement stringent filtration and lubrication routines.

At Custom Fluidpower, we specialise in delivering tailored fluid power solutions for Australia’s mining and coal industries. Our experts understand the unique challenges of operating in rugged, high-dust environments – and we’re here to help you keep your systems running reliably and efficiently.

Contact Us

Explore our full range of hydraulic services and products.
Let’s help you reduce downtime and boost operational reliability!

👉 Visit Custom Fluidpower for more information or to speak with a hydraulic systems expert today.