HYDRAULICS SYSTEM

DEALS WITH GENERATION, TRANSMISSION AND CONTROL OF POWER USING PRESSURISED FLUID (BY VIRTUE OF PASCALS LAW)

PNEUMATIC SYSTEM
DEALS WITH TRANSMISSION AND CONTROL OF POWER USING PRESSURISED AIR.
ELECTRICAL SYSTEM
DEALS WITH TRANSMISSION PNEUMATIC SYSTEM. AND CONTROL OF HYDRAULIC AND

Objectives
At the end of the course the candidate should be able to Understand & explain : The basics of hydraulics & pneumatics The comparison between electric , hydraulic & pneumatic systems Various components of a typical hydraulic and pneumatic circuit alongwith their symbols The working & construction of various hydraulic & pneumatic system components Some simple hydraulic & pneumatic circuits Some shipboard application of hydraulics & pneumatics Practical demonstration
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USES OF HYDRAULICS
Shipboard systems using hydraulic power
Steering gear: rudder, fairwater and stern planes Deck machinery: anchor windlass, capstans, winches, etc. Valve Actuators Mast and antennas on submarines Weapons systems: munitions loading and launching(guns, missiles, and torpedoes) Other: presses, elevators

PROPERTIES OF LIQUIDS Shapelessness

No natural shape Conforms to the shape of the container

Incompressibility Transmission of force

Force is equally distributed throughout the liquid

Fluid we use: 2190 TEP

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PASCALS LAW
Pressure in a fluid acts equally in all directions

PRESSURE = FORCE/AREA

Find Pressure Find F2

F2 = A 1 = 2 0 in2

F1 = 2 0 lbf A 1 = 2 in2

COMPARISONS OF

ELECTRICAL, HYDRAULIC AND PNEUMATIC SYSTEMS

Energy source Energy storage Energy cost Rotary actuators

Electrical Usually from outside supplier Limited (batteries) Lowest AC & DC motors. Good control on DC motors. Short motion via solenoid

Hydraulic Electric motor or diesel driven Limited (accumulator) Medium Low speed, Good control. Can be stalled Cylinders, Very high force

Pneumatic Electric motor or diesel driven Good (reservoir) Highest Wide speed range Accurate speed control difficult Cylinders. Medium force

Linear actuators

Controllable force

Possible with solenoid & DC

Controllable high force

Controllable Medium force

fire hazard

GRAPHIC SYMBOLS OF VARIOUS COMPONENTS

WORKING LINE

PILOT LINE
DRAIN LINE

CROSSING WORKING LINE

CROSSING WORK & PILOT LINE

CROSSING DRAIN LINE

ELECTRIC LINE

FLEXIBLE LINES

RESERVOIR

PIPE TERMINATED BELOW FLUID LEVEL

PIPE TERMINATED ABOVE FLUID LEVEL

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ENERGY FLOW HYDRAULIC ONE DIRECTION ONLY

ENERGY FLOW HYDRAULIC BOTH DIRECTIONS

ENERGY FLOW PNEUMATIC BOTH DIRECTIONS ENERGY FLOW PNEUMATIC ONE DIRECTION

FIXED RESTRICTION
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BASIC PUMP SYMBOL

FLOW LINES CONNECTED TO PUMP

SHAFT TURNS IN ONE DIRECTION

SHAFT TURNS IN BOTH DIRECTIONS

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HYDRAULIC PUMP UNIDIRECTIONAL

HYDRAULIC PUMP BIDIRECTIONAL

VARIABLE DISPLACEMENT UNIDIRECTIONAL

VARIABLE DISPLACEMENT BIDIRECTIONAL

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HYDRAULIC MOTOR UNIDIRECTIONAL

HYDRAULIC MOTOR BIDIRECTIONAL

VARIABLE DISPLACEMENT UNIDIRECTIONAL

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PRESSURISED RESERVOIR

TEMP. GAUGE

FLOW METER

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ACCUMULATOR

AUTO DRAIN

LUBRICATOR

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ELECTRIC MOTOR

HEAT ENGINE

FREE FLOW IN ONE DIRN, RESTD IN OTHER

PILOT LINE

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COOLER

HEATER

MANUAL SHUT OFF VALVE

VARIABLE FLOW CONTROL VALVE

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DIRECTIONAL CONTROL VALVES

TWO POSITION VALVE

THREE POSITION VALVE

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2\2 WAY VALVE

P

3\2 WAY VALVE

P T

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4\2 WAY VALVE

P
A B

4\3 WAY VALVE

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5\2 WAY VALVE

S P R

5\3 WAY VALVE

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PROPORTIONAL VALVE (4\3)

P T

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CYLINDERS

SINGLE ACTING

DOUBLE ACTING

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DIRECTIONAL CONTROL VALVES

THESE VALVES, AS THEIR NAMES IMPLIES, CONTROL THE DIRECTION OF FLOW OF THE FLUID IN THE SYSTEM. THESE ARE OF THREE TYPES :-

A. POSITIVE SEATED TYPE : IN WHICH A BALL OR PISTON MOVES ON OR OFF THE SEAT.
B. ROTORY SPOOL TYPE : IN WHICH THE SPOOL ROTATES ABOUT ITS OWN AXIS. C. SLIDING SPOOL TYPE : IN WHICH THE SPOOL MOVES AXIALLY IN A BORE.
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3/2 WAY DIRECTIONAL CONTROL VALVE (POPPET)

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3/2 WAY DIRECTIONAL CONTROL VALVA (POPPET)

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2/2 WAY DIRECTIONAL CONTROL VALVE (SPOOL)

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4/2 WAY DIRECTIONAL CONTROL VALVE (SPOOL)

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ROTOR R A R A A R

OFF B

4/3 WAY DIRECTIONAL CONTROL VALVE (ROTARY)

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PILOT OPERATED VALVES

LARGE CAPACITY PNEUMATIC VALVES AND HYDRALIC VALVES, THE OPERATING FORCE REQUIRED TO MOVE THE VALVE IS LARGE. IF THE REQUIRED FORCE IS TOO LARGE FOR A SOLONOID OR MANUAL OPERATION, A TWO STAGE PROCESS CALLED PILOT OPERATION IS USED.

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PILOT OPERATED VALVE

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SEQENCING VALVE

SEQUENCE VALVE IS A CLOSE RELATIVE OF THE PRESSURE RELIEF VALVE AND IS USED WHERE ASET OF OPERATIONS ARE REQUIRED TO BE CONTROLLED IN A PRESSURE RELATED SEQUENCE.

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SEQUENCING VALVE

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CHECK VALVES

CHECK VALVES ONLY ALLOW FLOW IN ONE DIRECTION AND, AS SUCH ARE SIMILAR IN OPERATION TO ELECTRONIC DIODES.

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CHECK VALVE

RIGHT ANGLE CHECK VALVE

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TIME DELAY VALVE TIME DELAY VALVES ARE USED TO DISPLAY OPERATIONS WHERE TIME BASED SEQUENCES ARE REQUIRED. THE TIME DELAY CAN BE ADJUSTED BY THE NEEDLE VALVE SETTING AS PER REQUIREMENT.

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TIME DELAY VALVE

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SHUTTLE VALVE

A SHUTTLE VALVE, ALSO KNOWN AS A DOUBLE CHECK VALVE, ALLOWS PRESSURE IN A LINE TO BE OBTAINED FROM ALTERNATIVE SOURCES. IT IS PRIMARILY A PNEUMATIC DEVICE AND IS RELY FOUND IN HYDRAULIC CIRCUITS.

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SHUTTLE VALVE

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EXHAUST VALVE

EXHAUST VALVES ARE USED TO VENT CYLINDERS QUICKLY. THESE VALVES ARE USUALLY MOUNTED LOCAL TO, OR DIRECTLY ONTO, CYLINDERS AND SPEED UP RESPONSE BY AVOIDING ANY DELAY FROM RETURN PIPES AND CONTROL VALVES.

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EXHAUST VALVE

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PROPORTIONAL VALVE

INPUT AND OUTPUT SINGAL.

ORIFICE/GROVES ARE PROVIDED ON SPOOL. EXTERNAL CIRCUIT REQUIRED e.g OPAM. HIGH CURRENT REQUIRED 120 TO 800mA. CLOSE LOOP AS WELL AS OPEN LOOP.

2-10% OF DEAD BAND i.e +ve DEAD BAND

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PRO

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RESTRICTORS RESTRICTORS ARE USED IN THE HYDRAULIC AND PNEUMATIC SYSTEM TO CONTROL THE SPEED OF ACTUATORS BY ADJUSTING THE RATE AT WHICH A FLUID ISADMITTED TO A DEVICE. THESE ARE OF TWO TYPES: FIXED RESTRICTORS VARIABLE RESTRICTORS
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MOTION DETECTORS THESE ARE BASICALLY PILOT VALVES USED IN PNEUMATIC SYSTEM FOR PILOT OPERATIONS, WHICH CONVERT MECHANICAL MOTION INTO PRESSURE CHANGE. THESE ARE OF TWO TYPES: BLEED TYPE (i) DIRECT ACTING

(ii) REVERSE ACTING

NON-BLEED TYPE
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BAFFLE/NOZZLE

BAFFLE/NOZZLE IS THE HEART OF ALL PNEUMATIC PROCESS CONTROL DEVICES TO CONVERT A SMALL DISPLACEMENT INTO A PRESSURE CHANGE, WHICH REPRESENTS THE PROPERTY CAUSING THE DISPLACEMENT INTO A PRESSURE CHANGE.

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AIR RELAY
DIRECT ACTING- BLEED TYPE
AIR RELAY BALANCES INPUT PRESSURE WITH HE FORCE FROM THE RANGE SPRING. AN INCREASING SIGNAL CAUSES AIR TO PASS FROM THE SUPPLY TO THE LOAD, WHILE A DECREASING INPUT SIGNAL CAUSES AIR TOVENTILATE FROM THE LOAD.

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PUMPS A PUMP TAKES OIL FROM A TANK AND DELIVERS IT TO THE REST OF THE HYDRAULIC CIRCUIT WITH RAISING OIL PRESSURE TO THE REQUIRED LEVEL. THERE ARE THREE TYPES OF POSITIVE DISPLACEMENT PUMPS USED IN HYDRAULIC SYSTEMS. GEAR PUMPS VANE PUMPS PISTON PUMPS
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GEAR PUMP
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PISTON PUMP
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VANE PUMP
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HYDRAULIC RESERVOIR A HYDRAULIC SYSTEM IS CLOSED, AND THE OIL USED IS STORED IN A TANK OR RESERVOIR TO WHICH IT IS RETURNED AFTER USE. THE MAIN FUNCTIONS OF THE RESERVOIR IN A HYDRAULIC SYSTEM ARE

TO STORE AND SUPPLY HYDRAULIC FLUID

TRANSFERING OF WASTE HEAT. AS A DEAERATOR. USED AS A PLATFORM.
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TO PUMP

DRAIN RETURN

ACCESS PLATE COARSE FILTER

BAFFLE PLATE

DRIP TRAY
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ACCUMULATOR

IT IS A RESERVOIR OF OIL AT SUPPLY PRESSURE. THE OIL IN IT IS PRESSURISED BY A BAG OF NITROGEN GAS. THE BAG IS PRE-CHARGED WITH GAS TO A PRESSURE OF HALF THE (PRESSURE OF) SYSTEM PRESSURE. FORCING OIL IN AT SYSTEM PRESSURE GAS IS COMPRESSED INSIDE THE ACCUMULATOR.

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GAS CHARGING VALVE

BLADDER

GAS FLUID

POPPET VALVE

PRESSURE SWITCH

TO SYSTEM

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PRESSURE CONTROL VALVES

THESE VALVES ARE USED TO REGULATE FLUID PRESSURE. THERE ARE TWO MAIN TYPES PRESSURE OF CONTROL VALVES. A. PRESSURE RELIEF VALVE B. PRESSURE REDUCING VALVE THE BASIC DIFFERENCE BEING THAT THE RELIEF VALVE IS CLOSED BY THE SPRING, AND THE REDUCING VALVE OPENED BY THE SPRING.

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PRESSURE RELIEF VALVE

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TWO WAY PRESSURE REGULATING

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THREE WAY PRESSURE REGULATOR

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DESIGN OF SIMPLE PNEUMATIC CIRCUIT

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DESIGN OF SIMPLE HYDRAULIC CIRCUIT

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PNEUMATIC AND HYDRAULIC CONTROL SYSTEM OF CPP SYSTEM IS USED TO CONTROL THE PROPELLER PITCH IN BOTH DIRECTIONS FROM ZERO TO MAXIMUM.

MAIN PARTS OF THE SYSTEM PUMPS : PROVIDED WITH TWO PUMPS. WHEN LEAD PUMP FAILS, MOTOR DRIVEN PP. (STAND BY) TAKES OVER THE CONTROL.
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PROPELLER :
SYSTEM IS PROVIDED WITH FIVE REMOVABLE BLADES BOLTED TO THE AFT FLANGE OF THE PROPELLER SHAFT.

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PNEUMATIC SYSTEM HYGIENE

AIR INLET FILTER TO BE CHECKED/CLEANED. AIR BOTTLE TO BE DRAINED DAILY. LUB OIL SEPERATOR TO BE DRAINED CLEAN FILTERS FITTED IN SYSTEM. CHECK THE LEVEL OF OIL IN THE AIR CHECK FOR LEAKAGE IN THE SYSTEM. CHECK THE NEEDLE VALVE OF THE FILTER. CHECK SAFETY VALVE OPERATION PERIODICALLY. SEPERATOR. REGULARLY.

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HYDRAULIC SYSTEM HYGIENE

INSPECT FILTER ELEMENTS DO NOT USE LEAKED FLUID

KEEP FRESH FLUID SAFE

USE CLEAN CONTAINERS, FUNNELS ETC. KEEP OPEN COMPONENTS FREE FROM DIRT USE PROPER FLUID AS RECOMMENDED

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KEEP NAKED FLAMES AWAY FROM THE SYSTEM. USE PROPER FLUID AS RECOMMENDED ALWAYS RUN SYSTEM WITH FILTER ELEMENTS CHECK SAFETY VALVE OPERATION PERIODICALLY.

CARRY OUT FLUID ANALYSIS PERIODICALLY

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COMMON FAULTS IN HYDRAULIC & PNEUMATIC SYSTEMS HYDRAULICS

EXCESSIVE VIBRATION OF PUMP. PUMP NOT DEVELOPING PRESSURE. ACTUATOR NOT MOVING.

SYSTEM NOT RESPONDING.

EXCESSIVE OIL TEMPERATURE. DIFFERENTIAL PRESSURE TOO HIGH. HUNTING OF SYSTEM
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PNEUMATICS EXCESSIVE VIBRATION OF COMPRESSURE. COMPRESSURE NOT DEVELOPING RESSURE. ACTUATOR NOT MOVING.

SYSTEM NOT RESPONDING

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FAULT DETECTION TECHNIQUES INCORRECT FLOW

NO FLOW
PP NOT RECEIVING FLUID PP DRIVE MOTOR NOT OPERATING

LOW FLOW
FLOW CONTROL V V. SET TOO LOW

EXCESSIVE FLOW
FLOW CONTROL VALVE SET TOO HIGH

RELIEF VALVE SET YOKE ACTUATING TOO LOW DEVICE INOPERATIVE RPM OF MOTOR INCORRECT INPROPER SIZE OF PP USED TO REPLACE PP.

PP TO DRIVE FLOW BYPASSING COUPLING SHEARED D.C. VALVE SET IN WRONG POSITION FLOW PASSING OVER RELIEF VALVE RPM OF MOTOR INCORRECT EXTERNAL LEAKAGE

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INCORRECT PRESSURE
LOW PRESSURE ERRATIC PRESSURE EXCESSIVE PR.
PRESSURE RELIEF V V EXISTS. PR. REDUCING V V SET TOO LOW. AIR IN FLUID. WORN RELIEF VALVE. PR. RELIEF V V MIS-ADJUSTMENT. PR. REDUCING V V DAMAGED.

PR.REDUCING V V DAMAGED.
PUMP DAMAGED.

CONTAMINATED FLUID.
DEFECTIVE PUMP.

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