Many plants consider a hydraulic leak normal and not a cause for concern. In some cases, small leaks do have something of an inevitability about them. However, even a small leak can cost you far more than you would expect. Here is a look at some of the hidden costs that come with even minor hydraulic leaks and why you need to mitigate them sooner than later.
1. The Cost of Replacing the Leaking Fluid
Replacing fluid in hydraulic systems is a normal procedure and part of any overall hydraulic system maintenance budget. Still, even a small hydraulic leak will add to this cost. Over time, you may find you're paying far too much to replace the fluid.
Consider that a small leak can still represent a loss of several gallons of fluid every month. That loss can turn into an unnecessary expenditure of a few thousand dollars every year. If you're dealing with multiple leaks, that expenditure can climb dramatically.
2. The Cost of Cleaning Up
Cleaning up after a leak eats away at the time you or others could spend doing something else productive. That labor comes at a cost, not just for the time someone uses in the process, but also for the items required to do the actual cleaning.
In some cases, the cleaning products and labor can cost far more than the cost of the fluid itself. This means cleaning up leaks can literally cost more than it's worth. Still, if you want to avoid some other issues, such as accidents, then cleaning up these leaks are a cost you will have to bear.
Disposing of the waste fluid can also come at a cost, especially if your plant operates under heavy waste disposal regulations. Proper disposal can cost a lot, and improper disposal can lead to fines.
3. The Cost of Dealing
With
Accidents
Hydraulic leaks are a safety hazard. Any area of your facility that has a hydraulic leak is an area that also has a high slip and fall risk. Those slip and falls can cost you a lot, especially if they happen frequently.
Your workers' compensation insurance costs can rise, you may have to deal with lawsuits, and the accident itself can lead to a full stop of operations for a time. All these costs can add up and, in the case of a lawsuit, those costs can ruin a business.
You can also have a fire risk on your hands as well if you're leaking highly flammable fluid. If your operations have a lot of hot surfaces or several ignition sources, then a fluid leak can become a fire waiting to happen. Any accident can lead to costly cleanup, repair, or a temporary stop to production.
4. The Cost of Lowered Equipment Efficiency
It may not always seem like it, but a fluid leak can cause your hydraulic system to work harder to compensate. When your equipment works harder, the potential for increased wear, increased energy costs, and decreased efficiency can affect your bottom line in numerous ways.
A small leak can lead to all these issues, and the leak itself can become worse if you don't deal with it sooner rather than later. When dealing with multiple leaks, the situation only becomes worse, and the costs only grow.
You may only look at the surface costs associated with a hydraulic leak, but the hidden costs can compound astronomically. If you have a leak, deal with it immediately. If you have frequent or multiple leaks, you may need upgrades or repairs to your hydraulic system.
In some cases, hydraulic leaks can occur because your hydraulic system isn't adequate to the needs of your plant. If you're overtaxing the system or constantly repairing it, you may need a
custom hydraulic system solution
. Contact Quad Fluid Dynamics, Inc., for your hydraulic system needs.
