Basic Hyd PDF

Basic Hydraulics
QUESTION:
What is a hydraulic system ?
ANSWER:
A hydraulic system is a means of using a
pressurised fluid to transmit power between the
place where the power is generated and the point
where it is used
ADVANTAGES OF HYDRAULICS
- Variable Speed
Most electric motors run at a constant speed. It is also desirable to operate an engine at
a constant speed. The actuator (Liner or rotary) of a hydraulic system, however, can be
driven from high speeds to reduced speeds by varying the pump delivery or using a
flow control valve.
- Reversiable
Few prime movers are reversible. Those that are reversiable usually must be slowed to
a complete stop before reversing them. A hydraulic actuator can be reversed instantly
while in full motion without damage.
- Overload Protection
The pressure relief valve in a hydraulic system protects it from overload damage. When
the load exceeds the valve setting, pump delivery is directed to a tank. The result is a
definite limit to torque or force output.
ADVANTAGES OF HYDRAULICS
- Small Packages
Hydraulic components, because of their high speed and pressure capabilities, can
provide high power output with very small weight and size.
- Can Be Stalled
Stalling an electric motor will cause damage or blow a fuse. Likewise, engines cannot
be stalled without the necessity for restarting. A hydraulic actuator, though, can be
stalled without damage when overload, and will start up immediately when the load is
reduced. During stall, the relief valve simply divert delivery from the pump to the tank.
PASCAL LAW
Pascal Law: Pressure applied on a confined fluid is
transmitted undiminished in all direction, and acts
with equal force on equal areas, and at right angles
to them.
2. A 10 lb. force is appliedto the
stopper with a surface area of
one square inch
1. The bottle is filled

with liquid, which is
3. This results in 10 lb of force not compressible
on every square inch of
surface area in the container
4. If the bottom has an area of

20 sq. in. and each square
inch is pushed on by 10lbs.
of force, the entire bottom
of the container receives
200 lbs push
Figure 1-1 Pressure (force per unit area) is transmitted throughout a confined fluid
COPYRIGHT C (2001) EATON CORPORATION

TRANSMITTING MOVEMENT
CREATING PRESSURE
PUMP ACTUATOR
CREATING PRESSURE
PUMP ACTUATOR
PRESSURE DEFINED
FORCE FORCE = PRESSURE x AREA
AREA
PRESSURE PRESSURE = FORCE ÷ AREA

PRESSURE DEFINED
1 kg
1 kg
LOW HIGH
PRESSURE PRESSURE
PRESSURE CALCULATION
FORCE (N)
PRESSURE (Pa) =
AREA (m2)
FORCE (kgf)
PRESSURE (bar) =
AREA (cm2)
HOW PRESSURE IS CREATED
ZERO FLOW RESISTANCE

PRESSURE CREATED BY LOAD
PRESSURE CREATED BY A SPRING LOADED VALVE
PRESSURE CREATED BY FLOW RESTRICTION
PRESSURE CREATED BY FLOW RESTRICTION
P1 P2
Q Q
A
P1 - P2 = ∆ P
∆ P ∝ A x Q2
ie: to double the flow requires
four times the pressure difference
PRESSURE CREATED BY A HEAD OF FLUID
WEIGHT
HEIGHT
PRESSURE = WEIGHT ÷ AREA
VOLUME x DENSITY
PRESSURE
AREA x HEIGHT
AREA
PRESSURE = (AREA x HEIGHT) x DENSITY ÷ AREA
PRESSURE = HEIGHT x DENSITY
For mineral oil ∆P = 0.1 bar / metre approx.

LIFTING A LOAD
F 1000
P = = = 100 kg/cm2
A 10 1000 kg
P 10 cm2
PUMP ACTUATOR
LIFTING A LOAD
? 1000 kg
100 kg/cm2 10 cm2
10 cm2
PUMP ACTUATOR
LIFTING A LOAD
1000 kg 1000 kg
100 kg/cm2 10 cm2
10 cm2
PUMP ACTUATOR
LIFTING A LOAD
F 1000
P = = = 10 kg/cm2
A 100 1000 kg
100 cm2
10 kg/cm2
10 cm2
PUMP ACTUATOR
FORCE MULTIPLICATION
F = P x A = 10 x 10 = 100 kg
1000 kg
100 kg
100 cm2
10 kg/cm2
10 cm2
PUMP ACTUATOR
FORCE MULTIPLICATION
1000 kg
100 kg F F
= P =
A A
100 cm2
10 kg/cm2
10 cm2
PUMP ACTUATOR
CONSERVATION OF ENERGY
F
Energy= Force x Distance of Movement
A fundamental law of physics states

W
that energy can neither be created
nor destroyed.
10 F
1
A
10
10 A
F x 10 = ENERGY = 10F x 1
PUMP ACTUATOR
HYDRAULIC MACHINE
PUMP ACTUATOR
HYDRAULIC MACHINE
PUMP ACTUATOR
HYDRAULIC MACHINE
PUMP ACTUATOR
HYDRAULIC MACHINE
PUMP ACTUATOR
HYDRAULIC MACHINE
PUMP ACTUATOR
FLOW AND VELOCITY
FLOW
VELOCITY =
AREA
VELOCITY
AREA
FLOW
PRESSURE AND LOAD
LOAD
PRESSURE =
AREA
LOAD
PRESSURE AREA
FLOW
VELOCITY =
AREA
LOAD
PRESSURE =
AREA
CAVITATION
-P
P=0
+P
HYDRAULIC SYSTEMS
MACHINE REQUIREMENT
CYLINDER
HAND PUMP
POWER DRIVEN PUMP
PUMP AND RESERVOIR
PUMP AND RESERVOIR
RELIEF VALVE
RELIEF VALVE
DIRECTIONAL VALVE
DIRECTIONAL VALVE
FLOW CONTROL VALVE
FILTER
SCHEMATIC REPRESENTATION
SCHEMATIC REPRESENTATION
M
POWER
POWER
HYDRAULIC
POWER OUT
MECHANICAL
POWER IN
POWER
HYDRAULIC
POWER OUT
HYDRAULIC POWER = FLOW x PRESSURE

MECHANICAL
POWER IN
PRESSURE ( bar ) x FLOW ( l/min )

POWER ( kW ) =
600
POWER
P1 P2
Q Q
POWER IN = P1 x Q POWER OUT = P2 x Q
IF P2 < P1 THEN (POWER OUT) < (POWER IN)
POWER DIFFERENCE = HEAT
FOR MINERAL OIL - 1ºC PER 17.5 bar ∆P Q1

RESERVOIRS, FLUIDS AND PRIME MOVERS
NEGATIVE HEAD RESERVOIR
FLOODED SUCTION RESERVOIR
IMMERSED PUMP
POSITIVE HEAD RESERVOIR
FLUID RESERVOIR
SUCTION RETURN
HYDRAULIC FLUIDS
HYDRAULIC
FLUID
WATER
WATER / OIL
MINERAL OIL
VEGETABLE OIL
SYNTHETIC
HYDRAULIC FLUIDS
LUBRICATION
HYDRAULIC
FLUID
WATER
WATER / OIL
MINERAL OIL
VEGETABLE OIL
SYNTHETIC
HYDRAULIC FLUIDS
HYDRAULIC
FLUID
TEMPERATURE
RANGE
WATER
WATER / OIL
MINERAL OIL
VEGETABLE OIL
SYNTHETIC
HYDRAULIC FLUIDS
HYDRAULIC NON
FLUID
CORROSIVE
WATER
WATER / OIL
MINERAL OIL
VEGETABLE OIL
SYNTHETIC
HYDRAULIC FLUIDS
HYDRAULIC
FLUID
FLAMMABILITY
WATER
WATER / OIL
MINERAL OIL
VEGETABLE OIL
SYNTHETIC
HYDRAULIC FLUIDS
HYDRAULIC
FLUID
ENVIRONMENTALLY FRIENDLY
WATER
WATER / OIL
MINERAL OIL
VEGETABLE OIL
SYNTHETIC
HYDRAULIC FLUIDS
HYDRAULIC COST
FLUID
WATER
WATER / OIL
MINERAL OIL
VEGETABLE OIL
SYNTHETIC
HYDRAULIC FLUIDS
Temp. Range
Flammability
HYDRAULIC
Lubrication
Ecological
Corrosion
FLUID
Cost
WATER
WATER / OIL
MINERAL OIL
VEGETABLE OIL
SYNTHETIC
PRIME MOVERS
400V 3ph AC PETROL DIESEL
EUROPE:
1000 RPM 1200 2400 RPM
1500 RPM
USA:
1200 RPM
1800 RPM
SIZE COMPARISON
100 kilowatt components
DIESEL ELECTRIC HYDRAULIC

CONDUCTORS
Steve Skinner, Eaton Hydraulics, Havant, UK

Copyright  Eaton Hydraulics 2000
CONDUCTOR INSIDE DIAMETER SELECTION CHART
100 BASED ON FORMULA
20000
90 GPM. X 0.3208
80 AREA (SQ. IN.) =
VELOCITY (FT./SEC.)
70
60
50
10000
40
9000
5 5 20
8000
7000 4 1/2 4 1/2

30 15
4 4
6000
3 1/2 3 1/2 10
9
5000 8
20 3 3 7
6
4000 2 1/2 2 1/2 5
4
15
2
2
1. If the line 3000
3
must handle 1 3/4

1 1/2
14 gpm 2
10 1 1/2
1 1/4 2
2000 9
1 1/4
8 1 MAXIMUM
1 .9
7
.8 RECOMMENDED
.7 VELOCITY 3
6 .6
3/4
7/8 FOR
.5 INTAKE LINES
5 3/4
.4
4
1000 5/8
1/2 .3
4
900 5
9/16
800 3/8 1/2 .2
6
700 3 7/16
7
600 3/8
1/4
.1 8
.09
500 .08
5/16 9
2 .07
1/8 .06 10
400 1/4 .05 3. a flow velocity of
.04 10 fps will result
300 .03
15
AREA OF PIPE, TUBE AND HOSE - SQ. IN.
FLOW - CUBIC INCHES PER MINUTE
.02
1
20
MAXIMUM
NOMINAL STANDARD PIPE SIZE
VELOCITY - FEET PER SECOND

FLOW - GALLONS PER MINUTE
200 1/8 RECOMMENDED

ACTUAL INSIDE DIAMETER OF
.75 .01 VELOCITY

.009
.008 FOR
.007 PRESSURELINES 30
.006
PIPE, TUBE AND
HOSE - INCHES
.005
.5
.004 40
100
.4
50
Figure 4-7 A Conductor inside diameter selection c hart

API PIPE
Nominal Size Pipe O.D. Inside Diameter

Double Extra
Schedule 40 Schedule 80 Schedule 160 Heavy
1/8 .405 .269 .215

1/4 .540 .364 .302
3/8 .675 .493 .423
1/2 .840 .622 .546 .466 .252
3/4 1.050 .824 .742 .614 .434
1 1.316 1.049 .957 .815 .599
1-1/4 1.660 1.380 1.278 1.160 .896
1-1/2 1.900 1.610 1.500 1.338 1.100
2 2.375 2.067 1.939 1.689 1.503
2-1/2 2.875 2.469 2.323 2.125 1.771
3 3.500 3.068 2.900 2.624
3-1/3 4.000 3.548 3.364
4 4.500 4.026 3.826 3.438
5 5.583 5.047 4.813 4.313 4.063
6 6.625 6.065 5.761 5.189
8 8.625 7.981 7.625 6.813
10 10.750 10.020 9.564 8.500
12 12.750 11.934 11.376 10.126
Figure 4-1 Pipe currently are sized by schedule number

PRESSURE RATINGS OF API PIPE
CONNECTION TYPE
Tapered Pipe As the tapered pipe is tightened an interference fit is created. This
seals the joint, however it is leak prone and is not recommended for
hydraulic systems
NPT threads engage

first on the tooth sides,
leaving a potential
spiral leak path
Straight Thread
O-ring Boss
NPTF threads first

engage at the tooth
root, eliminating the
spiral clearance
Figure 4-2 Hydraulic pipe threads

CONNECTION TYPE
Flange O-Ring
Threaded Pipe Flange
Pipe
O-Ring
Weld
Socket Welded Flange
Figure 4-3 Flanged connec tions for large pipe

CONNECTION TYPE
0
A. 37Flair B. Straight Thread O-Ring Fitting
C. O-Ring Compression Fiting D. Straight Thread O-Ring

Compression Fitting
E. ORS Face Seal Fitting

Nut Sleeve ORFS Adapter
Ferrule Face Seal O-Ring
Figure 4-4 Threaded fittings and connections used with tubing

CONNECTION TYPE
Basic
Flange
Joints
Gasket Gasket
Metal-to-Metal Joints
Figure 4-8 Flange gaskets and seals are typical static applications
Wire Braid Reinforcement
Flexible Hose
Inner
Tube
Carcass
Cover
Figure 4-5 Flexible hose is constructed in layers

SAE 100R1
Type A - This hose shall consist of an inner tune of oil resistant synthetic rubber, a single wire braid reinforcement,
and an oil and weather resistant synthetic cover. A ply or grade of suitable material may be used over the
inner tube and/or over the wire reinforcement to anchor the synthetic rubber to the wire.
Type AT - This hose shall be of the same construction as Type A, except having a cover designed to assemble
with fittings which do not require removal of the cover or portion thereof.
SAE 100R2
The hose shall consist of an inner tube of oil resistant synthetic rubber, steel wire reinforcement according to
hose type as detailed below, and an oil and weather resistant synthetic rubber cover. A ply or braid of suitable
material may be used over the inner tube and/or over the wire reinforcement to anchor the synthetic rubber to the
wire.
Type A - This hose shall have two braids of wire reinforcement.
Type B - This hose shall have two spiral plies and one braid of wire reinforcement.
with fittings which do not require removal of the cover portion thereof.
Type BT - This hose shall be of the same construction as Type B, except having a cover designed to assemble
with fittings that do not require removal of the cover or a portion thereof.
SAE 100R3
The hose shall consist of an inner tube of oil resistant synthetic rubber, two braids of suitable textile yarn, and an
oil and weather resistant synthetic rubber cover.
SAE 100R4
The hose shall consist of an inner tube of oil resistant synthetic rubber, a reinforcement consisting of ply or
plies of woven or braided textile fibers with a suitable spiral of body wire, and an oil and weather resistant
synthetic rubber cover.
SAE 100R5
The hose shall consist of an inner tube of oil resistant synthetic rubber and two textile braids separated by a high
tensile steel wire braid. All braids are to be impregnated with an oil and mildew resistant synthetic rubber
compound.
SAE 100R6
The hose shall consist of an inner tube of oil resistant synthetic rubber, one braided ply of suitable textile yarn,
and an oil and weather resistant synthetic rubber.
SAE 100R7
The hose shall consist of a thermoplastic inner tube resistant to hydraulic fluids with a suitable synthetic fiber
reinforcement and a hydraulic fluid and weather resistant thermoplastic cover.
SAE 100R8
SAE 100R9
Type A - This hose shall consist of an inner tube of oil resistant synthetic rubber, 4-spiral plies of wire wrapped in
alternating directions, and an oil and weather resistant synthetic rubber cover. A ply or braid of suitable material
may be used over the inner tube and/or over the wire reinforcement to anchor the synthetic rubber to the wire.
with fittings which do not require removal of the cover or a portion thereof.
SAE 100R10
SAE 100R11
This hose shall consist of an inner tube of oil resistant synthetic rubber, 4-spiral plies of wire wrapped in alternating
directions, and an oil and weather resistant synthetic rubber cover. A ply or braid of suitable material may be used
over the inner tube and/or the wire reinforcement to anchor the synthetic rubber to the wire.
SAE 100R12
Figure 4-6 description of 100R-type flexible hose

SAE 100R1
Type A - This hose shall consist of an inner tune of oil resistant synthetic rubber, a single wire braid reinforcement,
and an oil and weather resistant synthetic cover. A ply or grade of suitable material may be used over the
inner tube and/or over the wire reinforcement to anchor the synthetic rubber to the wire.
with fittings which do not require removal of the cover or portion thereof.
SAE 100R2
The hose shall consist of an inner tube of oil resistant synthetic rubber, steel wire reinforcement according to
hose type as detailed below, and an oil and weather resistant synthetic rubber cover. A ply or braid of suitable
material may be used over the inner tube and/or over the wire reinforcement to anchor the synthetic rubber to the
wire.
Type A - This hose shall have two braids of wire reinforcement.
Type B - This hose shall have two spiral plies and one braid of wire reinforcement.
with fittings which do not require removal of the cover portion thereof.
Type BT - This hose shall be of the same construction as Type B, except having a cover designed to assemble
with fittings that do not require removal of the cover or a portion thereof.
SAE 100R3
The hose shall consist of an inner tube of oil resistant synthetic rubber, two braids of suitable textile yarn, and an
oil and weather resistant synthetic rubber cover.
SAE 100R4
The hose shall consist of an inner tube of oil resistant synthetic rubber, a reinforcement consisting of ply or
plies of woven or braided textile fibers with a suitable spiral of body wire, and an oil and weather resistant
synthetic rubber cover.
SAE 100R5
The hose shall consist of an inner tube of oil resistant synthetic rubber and two textile braids separated by a high
tensile steel wire braid. All braids are to be impregnated with an oil and mildew resistant synthetic rubber
compound.
SAE 100R6
The hose shall consist of an inner tube of oil resistant synthetic rubber, one braided ply of suitable textile yarn,
and an oil and weather resistant synthetic rubber.
SAE 100R7
SAE 100R8
SAE 100R9
SAE 100R10
SAE 100R11
SAE 100R12
Figure 4-6 description of 100R-type flexible hose

HYDRAULIC SYMBOL
Steve Skinner, Eaton Hydraulics, Havant, UK

Copyright  Eaton Hydraulics 2000
HYDRAULIC SYMBOLS
PUMPS
Fixed Variable
Displacement Displacement
MOTORS & CYLINDERS
Fixed Variable
Displacement Displacement
Cylinder, Single Acting, Single Rod
Cylinder, Double Acting, Single Rod

HYDRAULIC SYMBOLS
VALVES
Pressure Directional Control Valve,

Relief Valve Three Position
Pressure Directional Control Valve,

Reducing Valve Two Position
Shut Off Valve

Check Valve
Flow Control Valve

HYDRAULIC SYMBOLS
MISCELLANEOUS UNITS
Filter Accumulator
Cooler Heater
Pressure Switch
Pressure
Gauge
Temperature M Electric Motor

Gauge
HYDRAULIC SYMBOL
BASIC CALCULATION FOR HYDRAULIC SYSTEM
PRACTICAL HYDRAULIC FORMULAE
Geometric Displacement (cm3/r) x Shaft Speed (r/min)

Geometric Flow Rate =
(l/min) 1000
(Pumps & Motors)
Flow Rate (l/min) x Pressure (bar)

Hydraulic Power (kW) =
600
Geometric Flow Rate Effective Area (cm2) x Piston Speed (m/min)

=
(l/min) 10
(Cylinders)
Theoretical Force (kgf) = Effective Area (cm2) x Pressure (bar)

(Cylinders)
Geometric Displacement (cm3/r) x Pressure (bar)

Theoretical Shaft Torque =
(Nm) 20π
HYDRAULIC SYSTEM CALCULATION
M
Given:
Cylinder Bore Area = 100 cm2
Cylinder Extension Speed = 100 cm/min
Cylinder Pushing Force = 20 MT
Electric Motor Power Supply = 415V/50Hz/3Ph
Calculation:
1. System Flow Requirement
Flow = Cylinder Travel Speed x Cylinder Bore Area

= 100 cm2 x 100 cm/min
= 10000 cm3 / min
= 10 lpm
2. System Pressure Requirement
Pressure = Force / Bore Area

= 20 MT / 100 cm2
= 20 x1000 kgf / 100 cm2
= 200 bar
3. Power Input Requirement
Power = (Flow x Pressure) / 600

= (10 lpm x 200 bar) / 600
= 3.3 kW
4. Hydraulic Pump Displacement
Displacement = Flow / Electric Shaft Speed

= 10 lpm / 1450 rpm
= (10 x1000 cm3 / min) / 1450 rpm
= 6.9 cc/rev.

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Basic Hydraulics

What is a hydraulic system ?

1. The bottle is filled

4. If the bottom has an area of

COPYRIGHT C (2001) EATON CORPORATION

FORCE FORCE = PRESSURE x AREA

PRESSURE PRESSURE = FORCE ÷ AREA

ZERO FLOW RESISTANCE

PRESSURE = HEIGHT x DENSITY

For mineral oil ∆P = 0.1 bar / metre approx.

100 kg/cm2 10 cm2

100 kg/cm2 10 cm2

A fundamental law of physics states

HYDRAULIC POWER = FLOW x PRESSURE

PRESSURE ( bar ) x FLOW ( l/min )

IF P2 < P1 THEN (POWER OUT) < (POWER IN)

POWER DIFFERENCE = HEAT

FOR MINERAL OIL - 1ºC PER 17.5 bar ∆P Q1

400V 3ph AC PETROL DIESEL

100 kilowatt components

DIESEL ELECTRIC HYDRAULIC

Steve Skinner, Eaton Hydraulics, Havant, UK

7000 4 1/2 4 1/2

must handle 1 3/4

VELOCITY - FEET PER SECOND

200 1/8 RECOMMENDED

.75 .01 VELOCITY

Figure 4-7 A Conductor inside diameter selection c hart

Nominal Size Pipe O.D. Inside Diameter

1/8 .405 .269 .215

Figure 4-1 Pipe currently are sized by schedule number

NPT threads engage

NPTF threads first

Figure 4-2 Hydraulic pipe threads

Socket Welded Flange

Figure 4-3 Flanged connec tions for large pipe

C. O-Ring Compression Fiting D. Straight Thread O-Ring

E. ORS Face Seal Fitting

Ferrule Face Seal O-Ring

Figure 4-4 Threaded fittings and connections used with tubing

Figure 4-5 Flexible hose is constructed in layers

Figure 4-6 description of 100R-type flexible hose

Figure 4-6 description of 100R-type flexible hose

Steve Skinner, Eaton Hydraulics, Havant, UK

MOTORS & CYLINDERS

Cylinder, Single Acting, Single Rod

Cylinder, Double Acting, Single Rod

Pressure Directional Control Valve,

Pressure Directional Control Valve,

Shut Off Valve

Flow Control Valve

Temperature M Electric Motor

Geometric Displacement (cm3/r) x Shaft Speed (r/min)

Flow Rate (l/min) x Pressure (bar)

Geometric Flow Rate Effective Area (cm2) x Piston Speed (m/min)

Theoretical Force (kgf) = Effective Area (cm2) x Pressure (bar)

Geometric Displacement (cm3/r) x Pressure (bar)

Flow = Cylinder Travel Speed x Cylinder Bore Area

2. System Pressure Requirement

Pressure = Force / Bore Area

3. Power Input Requirement

Power = (Flow x Pressure) / 600

4. Hydraulic Pump Displacement