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Why Is My Paper Machine Hydraulic System Overheating?
Release Time :
2026-02-17
Overheating in a paper machine hydraulic system is a common operational issue in pulp and paper mills. If oil temperature rises beyond the designed range, it can affect viscosity, component lubrication, sealing performance, and overall system stability. Understanding the root causes of hydraulic overheating is essential for maintaining consistent production and extending equipment service life.
1. Excessive Internal Leakage
Internal leakage is one of the primary causes of hydraulic system overheating. When hydraulic pumps, valves, or cylinders experience wear, clearances increase. Oil flows from high-pressure zones to low-pressure zones without performing useful work. This pressure loss converts mechanical energy into heat.
Common sources include:
Worn hydraulic pumps
Damaged directional or proportional valves
Cylinder seal deterioration
Regular inspection of volumetric efficiency and pressure stability can help detect leakage early.
2. Improper System Pressure Settings
If the relief valve is set too high or frequently in unloading condition, excessive pressure will generate unnecessary heat. In paper machines, hydraulic systems often operate continuously. Poor pressure calibration can lead to energy loss and continuous oil temperature rise.
It is important to verify system pressure against the design specification and confirm that relief valves are functioning correctly.
3. Inadequate Cooling Capacity
Paper machine hydraulic systems usually rely on oil coolers, either air-cooled or water-cooled. If the cooling system is undersized, blocked, or contaminated, heat dissipation becomes insufficient.
Check for:
Fouled heat exchanger surfaces
Reduced cooling water flow
Fan malfunction in air-cooled units
Scaling inside cooler tubes
Routine cleaning and flow monitoring are necessary to maintain proper heat exchange efficiency.
4. Oil Contamination and Degradation
Contaminated hydraulic oil increases friction and reduces lubrication performance. Particles, moisture, or oxidation byproducts can accelerate wear and raise operating temperature.
Using oil with improper viscosity also contributes to overheating. Oil that is too thin reduces sealing performance, while oil that is too thick increases flow resistance.
Periodic oil analysis helps monitor viscosity, contamination level, and chemical stability.
5. Excessive System Load
Paper machines involve tension control, roll positioning, and press section operations. If the hydraulic system is subjected to loads beyond its rated capacity, the pump may operate near maximum output for extended periods, generating additional heat.
Evaluate whether recent production adjustments, speed increases, or mechanical modifications have increased hydraulic demand.
6. Poor System Design or Aging Components
Older hydraulic systems may lack efficient heat management or modern load-sensing control. Continuous operation over many years can also reduce pump efficiency and increase friction losses.
Upgrading components or optimizing circuit design may improve overall thermal performance.
Recommended Troubleshooting Approach
To diagnose overheating effectively:
1. Measure oil temperature at multiple points.
2. Check pressure settings and pump efficiency.
3. Inspect cooling system performance.
4. Conduct oil analysis.
5. Review load conditions and duty cycles.
Hydraulic overheating is typically caused by a combination of factors rather than a single fault. A systematic evaluation of pressure, flow, cooling, and oil condition will help identify the root cause and restore stable operation.
Maintaining proper temperature control is essential for reliable paper machine performance and long-term equipment stability.
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