04 Mem341

MEM341: FLUID POWER TECHNOLOGY MEM341: FLUID POWER TECHNOLOGY MEM341: FLUID POWER TECHNOLOGY MEM341: FLUID POWER
TECHNOLOGY

EP Chiang
UiTMPP FKM
40
7. Ancillary Hydraulic Devices, Conductors and
Fittings

The major components of a hydraulic device are pumps, vales, actuators, conductors
and fittings. Beside these device, components such as, reservoirs, accumulators,
pressure intensifiers, sealing devices, heat exchangers, pressure gages, flow meters,
filters and strainers are also make up a complete hydraulic system.

Reservoirs
Serves as a storage space for the hydraulic fluid and also as the principal location where
the fluid is conditioned.
At reservoir, sludge, water, and metal chips settle and air is allowed to escape.

Sizing of reservoirs:
Must make allowance for dirt and chips
to settle and for air to escape.
Hold all the oil that might drain into the
reservoir from the system.
Maintain high oil level to prevent air
drawn into the pump.
Large surface to dissipate heat
generated by the system.
Space to allow for thermal expansion
of the oil.

In general practice, reservoir size is three times the volume flow-rate (in gpm or m3/min)

MEM341: FLUID POWER TECHNOLOGY MEM341: FLUID POWER TECHNOLOGY MEM341: FLUID POWER TECHNOLOGY MEM341: FLUID POWER TECHNOLOGY

EP Chiang
UiTMPP FKM
41

Figure: Reservoir and Fluid Power unit construction

Accumulators
A hydraulic accumulator is a pressure vessel used for storing fluid. (Potential energy)
Accumulators are used in a hydraulic system for one of the following reasons:
To meet peak demands of power.
Example if a smaller pump is used for a system but maybe at a certain time
more power is required.
To smooth out pressure surges
When there is a sudden change in fluid flow, this will cause vibration.
Accumulator will absorb the energy and dampen out these surges.
To provide emergency power sources.

Three basic types of accumulators:
1. Weight loaded or gravity type
Oldest design. Using a cylinder, piston and dead weight. The gravity force
provides the potential energy in the accumulator. Provide a constant fluid
pressure throughout the full volume output regardless of the rate and
quantity of output. Bulky in design.

EP Chiang
UiTMPP FKM
42
2. spring loaded type
Similar to the weight loaded type but except that the piston is preloaded with
a spring. Potential energy is provided by the compressed spring. Pressure
exerted on the fluid is not constant. Not suitable for high cycle rates
operations.

3. gas loaded type.
More practical that the weight and spring loaded types. Operates in
accordance with Boyles law of gases, which states that for a constant
temperature process, the pressure of a gas varies inversely with its volume.

Gas loaded accumulator has Two main categories, Non-separator type and separator
type.

Separator type accumulator is the most widely used. 3 design:
Piston type

Piston
Pressurized
hydraulic fluid
Spring
Counter
weight
Pressurized
hydraulic fluid
Piston

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UiTMPP FKM
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Diaphragm type

Bladder type

Pressure Intensifiers
Act as a booster to increase the fluid pressure available
from the supply source. Mostly as a cost saving
measurement.

Figure: Cut-away of a pressure intensifier

EP Chiang
UiTMPP FKM
44

Figure: Oil flow path in a pressure intensifier.

Heat Exchangers
Heat exchangers are used in hydraulic systems to maintain the operating temperature of
the fluid within specified limits. Excessive temperature hastens oxidation of hydraulic oil.
This promotes deterioration of seal s and accelerates wear between fitting parts of
hydraulic components. Can be used to cool hydraulic fluid or can also be used to
increase the temperature of hydraulic fluid when working in a cold climate. Normally,
hydraulic system will generate enough temperatures after initial warm-up period. Two
main types of heat dissipation heat exchangers: air coolers and water coolers.

Figure: Water cooled heat
exchangers
Figure: Air cooled heat

EP Chiang
UiTMPP FKM
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EP Chiang
UiTMPP FKM
46
Sizing of heat exchanger.
The heat energy generated internally by the hydraulic system equals the power input to
the pump minus the power consumed at the output, multiplied by the operation time. The
units used are usually British thermal units (Btu) or Joules.

( ) OHP IHP t Loss Energy =

Fluid Temperature Rise Across Pressure Relief Valves
Heat is generated when fluid passed through components such as relief valves and
friction of moving parts.
To find the temperature rise across pressure relief valves:

) / ( ) / (
) / (
0
s kg flowrate oil C kg kJ heat specific oil
s kW rate generation heat
increase e Temperatur
=

Filters and Strainers

The function of filters and strainers are to remove contamination.

Strainer is a coarse filter that functions to trap contamination. Strainers
are constructed of a wire screen that rarely contains openings less than
100 mesh. 100 == 0.0059 in. Strainers can only remove large particles,
and are usually installed in the pump suction line to remove contaminants.
Drop in pressure indicates that the strainer is becoming clogged.

Filters can remove particles sizes up to micrometers (~0.000039 in).

3 basic types of filtering methods:
1. Mechanical. Contains a metal or
cloth screen and are capable of
removing only relatively coarse
particles.
2. Absorbent. Using porous and
permeable materials (paper,
wood pulp, cellulose, etc). Can
remove vary fine particles.
3. Adsorbent. Using a surface
phenomenon where particles
have a tendency to cling to the
surface of the filter (clay,
chemically treated paper).
Figure below shows the four typical
locations where filters are installed
in hydraulic circuits 1 for proportional
flow and 3 for full flow filters.
Strainer

EP Chiang
UiTMPP FKM
47

Figure : Different type of filter placement.

Figure: Left shows pressure line filter and right shows return line filter.


EP Chiang
UiTMPP FKM
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Conductors and Fittings
In hydraulic system, the fluid flows through a distribution system consisting of conductors
and fittings, which carry the fluid from reservoir through operating components and back
to the reservoir. The pipe work must be able to withstand vibration and thermal
expansion (for supported but allow flexibility), sufficient size to pass the fluid without
excessive pressure lost. Fittings and bends should not produce excessive restriction to
the flow.

Primarily hydraulic system used 4 types of conductors:

Steel pipes
Steel tubing
Plastic tubing
Flexible hoses

Pipes are specified by their nominal bore diameter. Outer diameter depends upon the
wall thickness of the wall.
Tubes are specified by their outside diameter and they are made to the standard sizes.
Bore diameter depends on the wall thickness.

Figure: Hydraulic hoses.

EP Chiang
UiTMPP FKM
49

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UiTMPP FKM
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UiTMPP FKM
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Sealing Devices
In hydraulic system, oil leakage will reduce the efficiency and increased the power
losses. There are two types of leakages, internal leakage and external leakage. In
internal leakages, there are no oil losses to the system because the fluid will flow back to
the reservoir. Internal leakage mainly cause by tolerance exist between components.
External leakages represent loss of fluid from the system and are mainly because of
improper assembly of pie fittings.
Seals are used in hydraulic systems to prevent excessive internal and external leakage
and to keep out contamination. Some of the common sealing devices are listed below:
1. rings
2. Compression packings (V- and U- shapes)
3. Piston cup packings
4. Piston rings
5. Wiper rings
6. Gaskets

Figure: Several different sized O-rings.

EP Chiang
UiTMPP FKM
52

Figure: V-ring packet.

Figure: Application of V-ring packet.

Figure: Die-cast gaskets used for flanged joints.

EP Chiang
UiTMPP FKM
53
Figure: Static seal flange joint applications.

EP Chiang
UiTMPP FKM
54
Trouble shooting hydraulic system
- Normally by using hydraulic circuit tester which consist of flowmeter and pressure
gage.

Testing hydraulic system using tester consists of:
measure pump flow at no load conditions.
1. apply desired pressure with the tester load valve on each component to find out
how much of the fluid is not available for power because it may be:
a. flowing at a lower rate because of slippage to worn seats or weak or
improperly set springs.
b. Flowing over pressure relief valves.
c. Leaking past valve spools and seats back into the fluid supply reservoir.
d. Leaking past the cylinder packing or motor parts directly into the return
line without producing useful work.

Figure: Portable hydraulic circuit tester.


EP Chiang
UiTMPP FKM
55
Probable causes of hydraulic system problems

1. Noisy pump
a. Air entering pump inlet
b. Misalignment of pump and drive unit
c. Excessive oil viscosity
d. Dirty inlet strainer
e. Chattering relief valve
f. Damaged pump
g. Excessive pump speed
h. Loose or damaged inlet line

2. Low or erratic pressure
a. Air in the fluid
b. Pressure relief valve set too low
c. Pressure relief valve not properly seated
d. Leak in hydraulic line
e. Defective or worn pump
f. Defective or worn actuator

3. No pressure
a. Pump turning in wrong direction
b. Ruptured hydraulic line
c. Low oil level in reservoir
d. Pressure relief valve stuck open
e. Broken pump shaft
f. Full pump flow bypassed to tank (faulty valve or cylinder)

4. Actuator fails to move
a. Faulty pump
b. DCV failure
c. System pressure too low
d. Defective actuator
e. PRV stuck open
f. Actuator load is excessive
g. Check valve in backwards

5. Slow or erratic motion of actuator
a. Air in system
b. Viscosity too high
c. Worn or damaged pump
d. Pump speed too low
e. Excessive leakage through actuators or valves
f. Faulty or dirty FCV
g. Blocked air breather in reservoir
h. Low fluid level in reservoir
i. Faulty check valve
j. Defective pressure relief valve

EP Chiang
UiTMPP FKM
56
6. Overheating of hydraulic fluid
a. Heat exchanger turned off or faulty
b. Undersized components or piping
c. Incorrect fluid
d. Continuous operation of pressure relief valve
e. Overloaded system
f. Dirty fluid
g. Reservoir too small
h. Inadequate supply of oil in reservoir
i. Excessive pump speed
j. Clogged or inadequate sized air breather.

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MEM341: FLUID POWER TECHNOLOGY MEM341: FLUID POWER TECHNOLOGY MEM341: FLUID POWER TECHNOLOGY MEM341: FLUID POWER

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