2018

Clay Hydraulic Unit Automatic

Operation

Submitted by:
Sr.Insepction Engineers:
Mohammed Gamal Abd El-Hafiz
Mahmoud Mohammed Abd El-Samiea.

Under Supervision:
Technical Support Manager:
Eng. Mohammed Eid

Jul 15 M.Gamal
[Type the company name]
7/15/2018
 July 15, 2018

Introduction
This report will represent a simple notification about the clay stacker hydraulic unit, also it will indicates the
check that have been done for clay hydraulic unit, result of this check and actions that have been taken to
achieve the desired automatic operation for clay stacker hydraulic unit according to the current load.
a- Clay Stacker Equipment:
1- General Notification for stacker:
The clay stacker builds up a material heap in a longitudinal store, where the stacker arm is suspended around
a tilting point in a steel structure and partly balanced with a counterweight. The arm is moved up and down
by a hydraulic cylinder in such a manner, that the discharge end stacker arm is kept at a suitable distance over
the material heap, while the material are being deposited.
The cylinder is operated by a hydraulic pump station which is placed under the stacker arm.

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 July 15, 2018

2- Stacker Hydraulic Unit:

4
1 3

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1- Variable displacement pump with pressure controller DR (A10VSO 18 DR).

The pump is swashplate design and variable flow, the industrial range nominal pressure is 280 bar and the peak
pressure is 350 bar.

2- Pressure controller DR.

The constant pressure control serves to maintain a contant pressure in the hydraulic systemwithin the control range of
the pump, so the pump therefore supplies only the amount of hydraulic fluid required by the system.

3- Pressure relief valve (DBDS10 G 1X/315).

The DBD pressure relief valves are direct operated poppet seat valves, they are used to limit the pressure in the
hydraulic system. And the pressure setting up to 315 bar.

4- Proportional directional valves directed (4WRE6 E32-2X/G24K4/V).

The 4/3 proportional directional valves are operated by proprtional solenoids and removable coils controlled by either
external control electronics, the maximum operating pressure is 315 bar and maximum flow is 80 L/min.
The proportional valve contorl the forward and backward hydraulic cylinder movement with specific given speed step,
where the hydraulic speed step from 0 to 10 steps.

5- Hydraulic cylinder.
The hydraulic cylinder is designed to operate in a specific speed range which is 0.3 to 1 m/min.

b- Hydraulic unit check:

The compensator pressure, pump flow, relief pressure, cylinder speed and cylinder pressure from the piston
and piston rod side have been checked.
c- The check result:
By the hydraulic unit check the following items have been found:
1- The compensator pressure was higher than the relief valve pressure and this opposite to the hydraulic
circuit logic.
2- The pump flow was higher than the required where the cylinder up and down speed was adjusted to
be close to maximum designed speed (Designed speed from 0.3 to 1 m/min) .
Note: There no a flow meter to measure the pump flow so the adjusting screw length has been taken as a
reference, also the cylinder speed has been taken to be as a flow pump indication.
d- Action that have been taken:
1- The compensator pressure has been adjusted to be lower than the relief pressure (the pump compensator
pressure adjusted to be 215 bar and relief valve pressure adjusted to be 235 bar).
2- The pump flow has been decreased to adjust the cylinder speed (the cylinder speed decreased from
0.85m/min to be 0.6 m/min).

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e- Actions result:
Several trials with different actions have been made to detect the optimum parameters which achieve our
objective, so the clay stacker now operates in automatic mood completely under load.
Note:
The actual required pump pressure to keep the stacker in steady state with automatic mood is higher than the
designed operating pressure where the pump pressure should be less than 180 bar but the actual pump
pressure which able to accommodate the actual load is higher than 200 bar.
Conclusion:
The optimum parameters which achieve our objective (operation of clay stacker in full automatic mood) are:
 Pump Pressure to be adjusted at 210 bar.
 Relief pressure to be adjusted at 235 bar.
 Upper cylinder speed to be operated at step 6 which give 0.6 m/min.
 Down Cylinder Speed to be operated at step 2 which give 0.9 m/min (where the stacker structure is not
stable mechanically for speed step more than step 2).
Recommendation:
 The hydraulic unit should be cleaned regularly every week and the hydraulic unit doors must be closed
all the time.
 The stacker should be operated under full automatic mood with above mentioned operating parameters
to achieve chevron stacking, also to decrease the dust in the work environment inside the clay hangar,
which cause a negative effect on the labors and equipment.
 The mechanical adjusting screws which control the operating pump pressure and other parameters
should not be changed, and if necessary it should be done under supervision of the concerned
coworkers from the mechanical and electrical teams.
 By comparison between the clay and pozolana stackers hydraulic units, they required approximately the
same operating pressure without load (around 170 bar) and with load (around 210 bar) to keep the
stacker in full automatic mood, and this operating pressure is higher than the manufacture designed
operating pressure which is less than 180 bar, So the manufacture should be contacted to discusses
the operating parameters.
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