How to Troubleshoot the Waterjet?

High-pressure water jets are a versatile cutting method, such as plasma, laser and mechanical cutting machines. They can cut metal precisely without leaving a heat-affected zone (HAZ) compared to thermal cutting. This makes waterjets the preferred method for cutting metal parts for aerospace and construction applications where metallurgical changes may affect the integrity of the material.

As with other cutting technologies, water jet systems have changed dramatically over the past decade. The latest systems can cut faster, more accurately, and are more reliable in terms of extended uptime. Advances in engineering technology and advanced system diagnostics that warn of problems before they begin have made today's water jet systems more reliable than those designed a decade ago, resulting in more predictable maintenance and less downtime.

That said, as with any piece of machinery, problems are bound to arise from time to time. With some simple troubleshooting, most problems can be solved quickly.

The booster is probably the most difficult part of any water jet system to work on. Because it has more moving parts, it is more likely to go wrong. Some of the most common problems are excessive strokes, leaks and short seal life. Three other common problems with supercharger-based water jet systems are hydraulic failure, low water pressure and overheated hydraulic temperatures.

1. Short Seal Life

If the life of a high-pressure water seal seems short, there are steps you can take to help extend the maintenance interval.

Make sure the water quality is within satisfactory limits.

Verify that water pressure and volume meet requirements.

When replacing seals, clean all parts thoroughly to avoid debris.

Inspect high pressure cylinder ends for cracks.

Make sure the plunger bearings (or hydraulic cylinder) are not worn.

2. Low water pressure

You may also notice low water pressure coming in and out of the booster. It is normal for the pump pressure to drop as the water leaves the booster and the cutting head opens. However, if the pressure drops too low, you will need to take the following steps.

Verify that the orifice is not damaged or defective. Replace if necessary.

Make sure there are no leaks in the switching valve. If there is a leak, fix the leak.

Close the cutting head and make sure it does not stroke when pressurized. If stroking occurs, check the safety valve and high pressure piping for leaks and repair or replace if necessary. If there are no leaks, make sure the low and high pressure poppet valves are in good condition. If needed, repair or replace poppet valves.

Check the check valve and repair or replace if necessary.

There is usually a pressure switch to sense the pressure of the water against the booster as it flows toward the booster. If the system detects low pressure, the pump will shut down to protect the system from operating without sufficient pressure to the booster. If you experience this situation, follow these steps.

Make sure the utility water for the pump is turned on.

Replace the water filter.

Check for a faulty or clogged inlet water shut-off valve.

Following these troubleshooting tips will save your service technician time and money, and help you make more money.

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