~ I:: BASIC HYDRAULICS WORKSHOP ... FOR '" .. ~ ~ .r I \ ~ ~ """-I I t , ~'I ~ -- - -'" I ~ ( , ~ " ~,. . 201,"SIGMA", echnologyStreet,HiranandaniGardens,Powai,Mumbai-400 T 076.

5570 Fax : 91-22-25705547 E-mail: imtc.mumbai@barbership.comWebsite: imtcmumbai.org International Maritime Training Centre Tel. : 91-22-2570 . . . . - --" --J ,.. ~:

1" ~ Ii BASIC HYDRAULIC WORKSHOP RevO.O, CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. M 17. Hos 18. Se 19. 20. Advantages of hydraulic systems... ... ... ...1 Fundamental principles... ... .. . ... ... '" ... ... 2-7 Block diagram of hydraulic systfi!:i\ns... Component an d circuit symbols Hydraulic fluid Re 8 ..9-14 ;~".,16 INTERNATIONAL MARITIME TRAINING CENTRE

~ ;:: BASIC HYDRAULIC WORKSHOP /' RevO.O July 03 AIM OF THE COURSE: 1. 2. TO UNDERSTAND FUNDAMENTAL PRINCIPLES OF HYDRAULICS TO READ HYDRAULIC AND P NEUMATIC CIRCUIT DIAGRAMS WITH THE HELP OF SYMBOLS KNOW THE CONSTRUCTION COMPONE NTS USED IN HYDRAU FUNCTION OF IMPORTANT ~ ~ f; H 3. E ~ E ~ 4. 5. 6. 10. CONSTANT TORQUE WIT PRESSURE AND SPEEDoc FLOW 11. INBUILT SAFETY - actuator can be stalledrat full load (even if relief valve lifts - it will reset immediat ely when overIQi:~d removed. is 12. AUTOMATIC BRAKING - by blocking flow, no bra kes, linings etc. required. 13. CAN BE USED IN HAZARDOUS CONDITIONS. ~ r; ~ INTERNATIONAL MARITIME TRAINING CENTRE

BASIC HYDRAULIC WORKSHOP Re.{).O .hdy 03 PASCALS LAW Pressure applied to a confined fluid is transmitted undiminished in all directio ns, and acts with equal force on equal areas, and at right angles to,them 1. The bottle with a IIqui . is not com bottom an area each ushed on e, the entire receives a ~OOlb. push. , INTERNATIONALMARITIMETRAINING CENTRE 2 ~

BASIC HYDRAVUC WORKSHOP RevO.O July 03 FUNDAMENTAL PRINCIPLES 1. PASCAL'S LAW: Pressure exerted on a confined fluid is transmitted undiminished i n all direction and acts with equal force on equal areas & at right angles to th em. Hydraulics is a means of power tran,; Work is force acting through a distan~ . WORK = FORCE x OIST, 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 15. 1 H.P. = 746 WATTS = 16. KW = L.P.M. x BAR/600. 17. H.P. = G.P.M. x PSI x 0. 000583. 18. H.P. of a prime mover = GPM x PSI x 0.0007. INTERNA TION}\[MARITIME TRAINING CENTF<E 3

BASIC HYDRAULIC WORKSHOP RevO. 0 July 03 Hvdraulic Principle I: Movement de{!ends on Flow For anything to move in a hydraulic machine, the actuators must be supplied with fluid flow. Nothing moves without flow. 4' "" ~, ~, "" '" l ...,) .,..:?'., ,'.0;;.;/ This cylinder is retracted. It ca'h"eXt~l1g i: 9~lyjifittJ!3re%Ts"ffow into port A. If there is no flow into port A, the piston will not move. ~ INTERNATIONA[-IIIIARITIMETRAINlf..I~CENTRE 4

BASIC HYDRA VLIC WORKSHOP RevO.O July 03 Hvdraulic Principle II: Rate of Flow Determines S~eed Actuator speed depends upon rate of flow. The faster fluid fills the cylinder, t he faster the piston will move. The faster fluid fills the expanding spaces in a hydraulic motor, the faster the shaft will turn. --"-1-x=;r=;r0 Notice that in this case speed may be affected in one direction only. If the val ve shifts fully the other way, cylinder speed will be normal in the other direct ion. TAP B INTERNATIONAL MARITIME TRAINING CENTRE 5

BASIC HYDRAVUC WORKSHOP RevO.O July 03 Hvdraulic Principle III: Load Determines Pressure The pressure developed in an actuator depends on the load. That is, pressure wil l rise until the force is exerts on the piston in a cylinder can move the load. The greater the load, the higher the pressure will rise. 0 Or, the load may be normal but there is not enough pressure available to move it. The relief valve may be leaking or set too low. The pump may be slippin g its total volume. Other leaks in the system may be absorbing all pump output a nd preventing the pressure in the cylinder from rising enough to move the load. INTERNAtiONAL JJlARITIMETRAINING CENTRE 6

BASIC HYDRAULIC WORKSHOP RevO.O July 03 5. A pilot line operates a valve or other control. 4. A drain line returns leakage oil to the reservoirs 3. The pressure line is working line ---.. ---.. 1. The pu: Inlet Ii a worki line. " Pilot: In many cases, movem essure signal taken from the system. This line is shown siml a edrain line but not connected to tank thus we can differentiate between a drain line and a pilot line. The pilot line can be likened to the starting circuit of an electric motor - where control voltages are much less than the main motor voltage. i Piloting is done in two ways: Inte rnal - this is done from the same circuit as the one in which the component is l ocated. External - this is when the pilot signal is taken from another pumps' ci rcuit or from a remote location. INTERNATiONALMARITIMETRAINING CENTRE 7

BASIC HYDRAULIC WORKSHOP RevO.O July 03 BLOCK DIAGRAM OF HYDRAULIC SYSTEM: 9 ~ tJ PUMP Gear Vane Piston Hvd. Energy Pressure Control Direction Control Flow Control ACTUATOR Cylinder Motor .. ~ ~ ~ ~ ~ ~ ~ Mech. Mech. Energy ~ a. b. c. d. e. f. DIRE a. 1, b. 2 01 c. Diffe Manl FLOW C a. Meter in b. Meter o ut c. Bleed off d. Non-compensated e. Pressure compensated f. Pressure & temp. c ompensated. ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ J ~ INTERNATIONAL MARITIME TRAINING CENTRE 8 ~ ~

BASIC HYDRAULIC WORKSHOP RevO.O July 03 Circuit - Representation Using Graphical Symbols ~ Hydraulic motor . Pushing PuIH ng R 4 \-\ci I'ct -+ H't<! Flf CD Att Tilting Press'oll 1f 9 INTERNATIONALMARITIMETRAINING CENTRE ,.'O f219 -; eJ.e d Stq 1M u..

BASIC HYDRA VLlC WORKSHOP RevO.O July 03 1 ACTUA TORS & PUMPS ~ SINGLE ACTING CYLINDER SPRING EXTENSION j j j SINGLE ACTING CYLINDER SPRING RETURN j j 1 ] I 1 J j ~ TH j , -4 'I , .. "II 1 ~ I U ,- ... , ... IRECTION MP, FIXED ELiVERY 'ARIABLE DELIVERY, UNIDIRECTION PUMP VARIABLE DELIVER Y, BI DIRECTION PUMP ~ ~ 4 , 4 ~ INTERNATIONAL SEMI-ROTARY MOTOR BI DIRECTION MOTOR IIIIARlflME TRAINING CENTRE

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~ ~~r~Q,\iG &ml~e\.t ~ BASIC HYDRAVLIC WORKSHOP QU -:--'r. IJ.1kQJvo I-I~ 1-QLOVAett ~QL ~ rS ~ . . i'Q~ \A.I.l.1M. "Ql!tl RevO.O July 03 ~~ cf..tt~ . DIRECTIONALCONTROLS ~ 3 PORT, ~ ~ 2 PORT, 2 POSITIOND.C. v/v ~ ~ bCR &lL0~ ~u:1.0.' PJ~o,~~lA 2 POSITIOND.C. v/v ~ &w!'~~~' c. clliJ J>tt'lM P(U,o}M CCM"",QCtt~ PO&K~* ~\A.lwJ ':~ CENT) G~~-QM. . OAT CENTER) ll&&U\ w~ ~ p T . ~ M~~~ Q~O \II" ," IC,I\t\.o lMr..~ r~V\ P

T D" (I_A ~JU~ t+'f4 ~~ ) r.". ~ (\J 1\1 Bod ~) ~p~ IN\) Ch? POgnl1rN 11 1os.&-.\k ie ok ~~d at (lJ..\~ ~~,&t~ pl)~"V\' INTERNATIONALMARITIMETRAINING CENTRE: 1--\"1 Nt> ~~ f~~,s ~ NORMf\U-1 ) 3 ~ \J \l\1 PNEU m It'" (. ~ MkLLf 2. PB6~ \J tv

BASIC HYDRAULIC WORKSHOP RevO.O July 03 METHODS OF OPERATION t=[ CJ=[ MANUAL SOLENOID cz{ PUSH BUTTON q $ COOLER iLJ RESERVOIR INTERNATIONAL MARITIME TRAINING CENTRE 12

BASIC HYDRA ULIC WORKSHOP RevO.O July 03 PRESSURE CONTROLS Name Pilot INTERNAL Drain INTERNAL ~ RELIEF VALVE Limits max. syste. pressure UNLOADING v/v . EXTERNAL INTERNAL Q --13 e " ~()~6{J CCM~ G &0~llo. \ ~ku V/\J

BASIC HYDRAULIC WORKSHOP RevO.O July 03 FLOW CONTROLS 0) @2Jm'" CHECK VALVE PILOI OPERTED CHECK VALVE 6PUMP MOTOR UNIT (FLOW DIVIDER) INTERNATIONAL MARitiME TRAINING CENTRE 14

BASIC HYDRAULIC WORKSHOP RevO.O July 03 FUNCTIONS AND PROPERTIES OF HYDRAULIC OIL FUNCTIONS: 1. 2. 3. TRANSMITS POWER LUBRICATES COMPONENTS REMOVES AND AIDS IN DISSIPA HEAT FROM THE SYSTEM 4. 5. 6. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. COMPRESSIBILITY Additives are added to the oil to improve the abo~e pr operties and thus extend the life of the oil. . H~.d INTERNATIONAL 4Q,Q \U:C'St~ ~UQ!J'M ([. 't-uite! 15 MARITIME TRAINING CENTRE

BASIC HYDRAULIC WORKSHOP RevO.O July 03 I:' &' EFFECT OF VISCOSITY ON HYDRAULIC SYSTEMS: IF THE VISCOSITY IS TOO HIGH: 1. The internal friction of the fluid will increas e resulting in increase in the flow resistance. The machine and fluid temperat~r e will increase. Ii" "'.. .. "t: 2. 3. 4. t: ~ ... E: c ~ ~ 'I ... t C , ... 1. 2. 3. ~uIJiIP~~ltp. .# e'wu,i1,:f" >.;. '" '\4;;" t. "" ? .~ {[ willlpdrease c{ndTeduc~pu):np'efficiency . and~ ~ . 1 ~~f1Joi.~iemr?er~t~je.. ~ ;1.:.., ~ "ii A~

"'II \, ... \e . a~ ~ 1 ... 4. ... >~ .of .. ,. .. -4 ... . 5. '11 a loss.."ofprecise o,ontrol. '" b~ "~a;.",. )i.' ~ ... w G -1) \h~c:~ 11"1 \N.bf)( : ~~ (i.".' '" .""". ...,... )"f. . i'~~'e(~~~~ ~ '0 ~ -to ~ \11 ~-eA. t-16 (~)

q ~. . . ~ INTERNATIONAL. -JIJIARltIME TRAfNING CENTRE 16

BASIC HYDRA ULlC WORKSHOP RevO.O July 03 IMPORTANCE OF RESERVOIRS RESERVOIR: Functions: 1. To aid in expelling entrained ai.. 2. Cooling the hydraulic 3. Aids in,removi n 1. Tank 2. It s en 3. B Ii 4. 5. 6. 7. ~~~t ~~cJ $00 ppt\Iv\ . INTERNATIONAL MARITIME TRAINING CENTRE 17

BASIC HYDRAULIC WORKSHOP RevO.O July 03 PUMP INLET LINE(OPTION) \ RETURN LINE SEALED FLANGE THERMOMETER AND SIGHT GLASS END PLATE EXTENSION Typical Industrial Reservoir INTERNATIONAL MARITIME TRAINING CENTRE 18

I BASIC HYDRAULIC WORKSHOP RevO.O July 03 FILTERS AND CONTAMINANTS Filter types: 1. 2. 3. 4. 5. 6. 7. Suction line filter - about 100 - po microns. . . Pressure line filter - about 5 - 1 Icrons. Return line filter - about 20 - 4 Icrons. Off line filtration. Full flow filters. PropoJ&tiJilaal flo Filte Maximum abrasion occurs due to particles slightly smaller or the same size as th e clearance between moving parts. r Q ~ I~ r~~ ~ i lie . e>( feu ~ cAP. ~~ ~ ~+u *(~" HL7l-~ . ::: rS[ Mea.w. ~ I'Xd'1 :/-5 paJ-;C& t'1 \Ai.d-f I"", PtLU 0,/.4~ 19 j 1/.iM 1~R.CtN.!.1'<2. +S/I

INTERNATIONALMARITIME TRAINING CENTRE

BASICHYDRAULIC WORKSHOP RevO.O July 03 AIR BREATHER START ... TO AVOID THE INGRESS OF CONTAMINATIONFROM AIR ENTERS THROUGH THE PERFORATIONS IN THE ./i THEATMOSPHERE A BREATHER IS USED BREATHER PASSES THROUGH THE ELEMENT, .THEN INTO THE RESERVOIR

INLET FILTER START FLU ID ENTERS THE , THEN PASSES INTO FILTER HOUSING fI,oANDFINALLY THROUGH THEFILTER I j I tlLTER ELEMENT I p,.;f;r~ \,,-,1 " " j.,\\ . "l.o;')~ I , , 1 AS THE FILTER CLOGS ,)---, mtS) '.',t\" WITHCONT.A.MINATION, THE PRESSURE DIFFRENCE ACROSS THE ELEMENT INCREASES ! j I \ ~~!)~.~'_~:1.: ! , , ,~'..~ " \,' i 'j r

~, I \ I . \,:\ , : J \!' ;! i:' ~: , ' ! I' -,r-i:-:-:"'~'1, ._." i . .. . , ' :'li>.1 UiJ,\i ' ~,;/".! 11' rJ' ~'~' .'. 'o;~ ~.! , I ,I , , ,::;";;" !p'~"i ' " , , , ~. p j Ii ~~?::> !'h' ~ I., ' ).{! 1,1 , )-.! r'7::,,~.(\\\j ;::/;;\1 '~\

f~\ -; I; (11 f ':':: , I' 1 iJ ~ Ii , ~:::) , , , ~~_::::::::;::>-~ , LL '... i' "-~;.,:>'~"I.t'L\' _1 I; '1' 'I' " ! 11 I I I ' , : r~"-r-:-".~;'-~.,,',' .,y, ',' .",' , ,j ,;, &""-.:""\1 ':~t:"" <,<\J 'S" 0 '[ ' 1_'(..:;'. . \., , ,, l tFfl \ , ,j -~-~ ~ ,-~ ::;::: ">:;:.';:::;' = "f i,t., ,:;1 " ~1i /;

" , tlJ1, ::; ' i , J.,L0 , " THISINCREASE CAUSES THE BY-PASSTO OPEN ALLOWING FLUIDACROSS THE BY.PASS I I ,I I ~ : -) 'J I ~~' -" r hii t " '--"";::;::> JO,' 'I.'! I~ + i .. ~'i~~~ , ~ 1.l " '! ,., r , :' I , l!l) , , 1 I ' i ' , ,

" I I ~ ~--F7"{_.) ' , , .,""""""~< " -' :' :' "1' ""' ," , (; i;~:! AS THE BY-PASS OPERATES, J i:1 "' ISALSO ANINDICATOR . :,..::.J:!j/l' \ ' ' , , "\'1" ~~.~~ ~ .,\ , ~ "-\' , "'1 r-t-, I ;J. I 1 , ",\ ,:,,:: \ .'" '" f " "-",, MOVED I J ] GREEN INDICATESTHE ELEMENT YELLOW INDICATES PARTIALBY-PASS& RED INDICATESFULLY BY-PASSING i C~:, .. ... I

RETURN LINE FILTER START .. FLUID ENTERS THE FILTER AND FLOWS INTO THE BOWL CONTAINING THE FILTER ELEMENT FLUID THEN PASSES THROUGH THE ELEMENT AND OUT OF THE FILTER AS THE ELEMENT CLOGS WITH CONTAMINATION THE RESISTANCE TO FLOW INCREASES AT A POINT DETERMINED BY THE SPRING TENSION, THE BY-PASS .. VALVE OPENS THUS PRO TECTING THE FILTER FROM COLLAPSE 'THIS CAUSES A RISE IN PRESSURE

BASIC HYDRA ULIC WORKSHOP RevO.O July 03 Hydraulic Fluid Cleanliness Requirements Cleanliness requirements for hydraulic fluids have changed significantly in rece nt years. The standard of cleanliness that was acceptable a few years ago is no longer sufficient for many of today's hydraulic systems. This is especially true for highly-automated facilities, such as electrohydraulic servo valves, numeric ally controlled machines, and aircraft and missiles system. A hydraulic system m ay be perfect with respect to the design and construction, but if the fluid that is used in the system contains excessive contamination, either the operation of the equipment may be unsatisfactory or damage to the unit may occur used by var ious organization and individual A number of different classification system hav e il for the hydraulic and lubricating fluids that companies to define and measu re the cleanlines are used in equipment. To standardize the me od used to expres s the level of particulate rds Organization (ISO) developed contamination in hyd raulic fluid, the" .' rd that not only expresses standard IS04406. ISO 4406 i to s pecitVwthe required the level of particulate cont cleanliness wides a consistent Hydr; custc clear recol follow hydral Drums. dirt and ( Drums s effects of The top of1 from falling i Hydraulic oi Equipment pumps, etc of any hOSE be thoroughlyCieaned prior be covered after use to prevent f Because many facili ties use different typ'es1'ofjiflyara~nc'&fj'UIas in different system, equipment that is used to transfer fluid to these systems should be designatedand used fo r each different fluid to prevent cross-contaminatingnoncompatiblefluids. Even t hough fluid suppliers are careful to deliver only clean fluid, a filtration syst em should be used to transfer the fluid to the reservoir. The degree of,filtrati on should be the same as the filtration system that is used on the equipment. Ma nl, fluid suppliers will provide hydraulic fluid filtration system specifically designedfor filtering fluid as it is added to the system. Facilities should esta blish and follow hydraulic fluid standards and practices to prevent the contamination of hydraulic system from the improper storage and handling of hydr aulic fluids.

BASIC HYDRAULIC WORKSHOP RevO.O July 03 INGRESS FROM CYLINDER ROD SEALS t PUMP INLET LINE FILTER PUMP TENDS TO GRIND EXISTING D!RT AND GENERATE MORE AS A RESUL BASIC FILTRATION OF A HYDRAULIC SYSTEM

W N (;) W N Q W W w .... W 25 ~ :z: <.: ;:;:.6 1-'" a: \.3 W ti; w a: '" IJJ a: I::::; :d ::;: a: w a.. </) w (j ~ 5 5 <.: :r roc w ;;;;: z ~ oc </) " :; w oc r:; ::::; ;n oc w a.. Q if u. 0 a: w tP ::wi IE t3 -' ~ if a: ill m ::;: tL 0 3 ~ t2 ::! :z: 5 to

15 20 25 30 4{) 50 . 60 70 80 00 100 PARTICLE SIZE, mlcrometres ISO solid contaminant code. Example: Sample size = 100 ml Particle size ranQe 5-15/lm 15 - 25 /l m 25 -: 50 /l m 50 - 100 /l m >100/lm Number of particles 150,000 5,000 1,250 250 50 [ Thus, total number of particles... . > 5 /l m = 156,550 >15 J.1 = 6,550 m These two values are plotted on the graph as shown, which give s the code as '18/13'

BASIC HYDRAULIC WORKSHOP R, Number of partioles per 100 mlllllltrns Code 20/17 20/16 20/15 20/14 19/16 19/15 19/14 19/13 18/15 18114 18/13 18/12 17/14 17/13 Over 5 p.m More than & up to 500k 500k 500k 500k 250k 250k 2501< 250k 1301<. 130k 130k 130k 64k 64k 64k 641< Over 15 p'm More than & up to 64k 32k 16k 8k 32k 16k 81< I 1M 1M 1M '1 M 500k 500k 500k 500k 250k 250k 250k 250k 130k 130k 130k 130k 1301< 64k 16k I 41< 16k 8k 41< 21< 8k 4k 2k 11\ 8k 32k 16k 8k 4k 161< 81< 4k 21< 32k 32k 16/11 16/10 15/12 64k 64k 64k 64k 32k 32k 4k 2k 1k 500 2k Ik 32k 32k 2k I I 11\ 4k 21< "16k '16k 16k 15/11 15/10 15/9 14/11 16k 8k I

32k 32k 16k 500 250 11< 1k 500 21< 14/10 14/9 14/8 13/10 13/9 1318 12/9 12/8 11/8 8k 81\ 8k 4k 4k 4k 2k 16k 16k 16k 8k 8k 8k 4k 4k 2k 500 250 130 500 250 {130 250 130 130 1k 500 250 1k 500 250 500 250 250 TABLE OF ISO CODES AND CORRESPONDING CONTAMINATIONLEVELS INI~Rr-rATIONAL MARITIMETRAINING CENTRE

BASIC HYDRAULIC WORKSHOP RevO.O July 03 3.1 Classification systems for the degree of contamination in a fluid Classifica tion systems (standardized cleanliness classes) are used to help determine the a mount of solid particles present in a fluid. The most commonly used standards to day are NAS 1638 and ISO DIS 4406. 3.1.1 Classification to NAS 1638 Fourteen cle anliness clas classify fluids. number of pa . each of 5 range1 Table 6 shows' ar e formed to 3.1.2 Classification to ISO DIS4406 Here the sizes larger than 5 11mand larger than 15 11mare cumulatively provided. The cleanliness class of the fluid is determined on the basis of both particle counts. are available for Twenty-six ranges classification. The designation of t he s class comprises only two first nym!:>er indicates the . Ie size larger mber indicates than 15 11m. 'i. ~ , , , ~ ~ ~ . ~ ~ , . . . ~ ~ . . ~ Cleanliness class 00 0 1 2 3 4 5 6 7 8 9 10 11 12 5-15 125 250 500 1000 : 2000 4000 8000 16000 32000 64000 128000 256000 512000 10 24000 Table6: Cleanliness clas Maximum numberofdirtp 1 2 5 10 15 20 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 " :J 2 1 . . . . ~ ~ Pr~cticle size in 11m Diagram 1: Cleanliness classes to ISO DIS 4406 Both classification systems may be represented graphically.

BASIC HYDRAULIC WORKSHOP RevO.O July 03 Q: What should be the Hydraulic Oil Cleanliness Standard for our type of Hydraulic System? And what should be the micron ratings of the Filter for such s ystems? A: Following are the recommended Oil Cleanliness Levels for different Hy draulic Systems and absolute micron ratings of the filters used in the system. H owever as a thumb. rule Oil Cleanliness Level required for the most sensitive co mponent of the system should be maintained. Recommended Oil Cleanliness levels f or different Components are as per next tabl rt for SYSTEMS Sr. No. :0Attainable Oil cleanliness s '---ISO 4406 1 2 3 1 2 3 4 5 6 7 8 9. 10 Ge Cy Di Rei Throttle Valves Piston Pumps Vane Pumps Proportional Valves Servo V alves Servo Cylinders 9 9 if) 19/16 18/15 18/15 18/15 16/13 16/13 20 20 20 20 20 10 10 5 3 3 -. 7 7 Source: Principles & Application of Hydraulic FiltersINTERNATiONAL MARITIME TRAINING CENTRE 28

!-; ~ h ~ ~ BASIC HYDRAULIC WORKSHOP RevO.O July 03 ~ ~ ~ STANDARD NAS ISO 1638 4406 Contamination 00 0 1 2 3 4 5 6 7 8 9 1 Number of Particles per 100 MLof Oil. MICRONRANGE 5 to15 125 250 500 10 15 to 25 2 25 to 50 4 8 16 32 50 to 100 1 2 3 6 1 >100 1 1 2 4 8 16 32 64 128 56 ,12 24 -

BASIC HYDRAULIC WORKSHOP RevO.O July 03 -... ....... TYPES OF PUMPS ~ -~ Hydrostatic Positivedisplacement Reciprocating Hi-press., low speed 250/500 strokes/min upto 700 bar ~ Hydrodynamic Non-positivedisplacement Centrifugal Rotary Axialflow ee-. .... ~ ~ 0f;'External Hi speed, Hi volume Low press. upto 200 bar c--e--. 0"-~ c-.C'c--~ ~ c-.. ~ ~ -~ ;-4r"" C" ~ ~ C-

BASIC HYDRAULIC WORKSHOP RevO.O July I COMMON PROBLEMS WITH PUMPS: 1. 2. Contqrnination - This willresult in I clearances. Cavitation of lubricatio n & increase in 3. INTERNATIONAL ARITIME TRAINING CENTRE M 31

BASIC HYDRAULIC WORKSHOP RevO.O July 03 SIMPLE POSITIVE DISPLACEMENT PUMP START BY PULLING THE PISTON ROD NUT . , THIS IS A POSITIVE DISPLACEMENT PUMP AS THERE IS A MECHANICAL SEAL (BALL VALVES) BETWEEN THE INLET AND OUTLET PORTS OF THE PUMP THERE IS VACUUM CREATED IN THE CHAMBER 4. 3' IF A PIPE CONNECTED TO A SUPPLY TANK WERE CONNECTED TO THE CHAMBER ! THEN FLUID WOULD BE PUSHED INTO THE CHAMBER BY ATMOSPHERIC PRESSURE , \ WITH THE FURTHER INCREASE IN PRESSURE THE DISCHARGE VALVE WOULD OPEN ALLOWING TH E TRAPPED VOLUME OF FLUID IN THE CHAMBER TO BE DISCHARGED TO THE ACTUATOR ~ WHICH WOULD UPSET THE BALL VALVE AND FLUID WOULD ENTER THE CHAMBER IF THE PLUNGER WAS PUSHED FORWARD THE PRESSURE WOULD RISE' IN THE CHAMBER ABOVE r ... THIS WOULD CAUSE THE BALL VALVE TO REST 1. INLET 2. OUTLET 3. PUMPINGCHAMBER 4.. MECHANISIMTO ACTIVATETHE-PUMPINGCHAMBER INTERNATIONAL MARITIME TRAINING CENTRE 32

BASIC HYDRAULIC WORKSHOP RevO.O July 03 DIRECTION CONTROL VALVES These valves start, stop and control the direction (path) of fluid flow. They ar e classified according to their principal characteristics as given below: 1. Typ e of internal valving element: a. Poppet (ball or piston) b. Rotary spool c. Sli ding spool (this is th 2. 3. 4. T Four port, two position valve I Four port, three position valve INTERNA TIONACMARITIME TRAINING CENTRE 33

BASIC HYDRAULIC WORKSHOP RevO.O July 03 TWO - POSITION FOUR PORT VALVE A. B A B 3 It p,,~ i I X ITIJ P T '<;). 2. ~'~ Th. ne... pol1-..., P'A ."d a.T !ly ,cd.nq lel/f't.., .u Ih, ;><,":bl, ne... $'111\'wllh II<,."" II th. u",""" t". tOIi" i. lev' Giv\"~ . lovf WI)' 1 ev 'h'!tJn~ tl->.."'=< oc'".. ",..0 ,/I.",.".,. 110-.0. POI'" 1~ ",1" It A~T' . Ih tnoYI"1I". .pool .. to ,!>I. '!V.Ih,~ p<>lftJon To'Qfl0" pc,!1j III 1V'f1,.blt Lt. '.~A..T j INTERNATIONAL MARITIME TRAINING CENTRE 34

BASIC HYDRAULIC WORKSHOP RevO.O July 03 THREE - POSITION4 - WAYVALVES Three position valves, with center neutral, are used in circuits where the cylin der must be stopped in mid travel. The 3 - position valve pictured below has all ports blocked in center neutral, but several other choices of center porting ar e commonly used, and these are illustrated in diagrams on the following pages. T he two side positions give the same cylinder reversing action as the two - posit ion valve previously described. The center position is considered the "normal" p osition, a.!1!d drawing diagrams, all external circuit in connections should be made to the center bl {Tj Tank Tank Spoof Can1zr Portini Di.Jgram; Portini Diagram lor' m I j I . Por1In9 Ol.gram for ldt Spcol Position A 8 All Poru Block.d. S Right SpOol Position '. A a I -OO---l . T I r-~ PiT P T I A II [~[ Mallu,' LI"'" SQllnoid Spf'.c.nt. I B lev., Spr.Cent. p

T Trli.!ldl. Actuato; Jj~A B Pilot Oper. Spr. Cant; S<:>lenoid Spr. Cant. The three flow blocks s flow in the three working pOSt are placed side by side, then actuator symbols are added on one or both ends as needed. The valve shown i s a double solenoid, spring centered valve with closed center spool. p T INTERNATIONAL MARITIME 'tRAINING CENTRE 35

BASIC HYDRAUliC WORKSHOP RiMI0.hJ; 03 SOLENOIDS FOR DIRECTION CONTROL VALVE ACTUATION. These are the most common actuators for direction control valves. The ones used in this application are of the 'on - off' type. The solenoids always actuate the spool by PUSHING on it. They can be DC (generally round s~';pe & black) or AC ( generally flat sided and blue) Solenoids are made u~ the suppl~}naQd th Two sol Air gap t .. system. . help of with t Wet sole sun (whl mar into arm about In both tl its end p (A.C. C Reasons 1. Contamination in med. 2. Misalignment between solenOI ange & spool. 3. All 4 bolts of above flange not equally tight. 4. Excessive ambient temperatu re. 5. If both coils are energised at the same time (this is normally prevented with an interlock arrangement - but to be safe, both supply wires should not run together. INTERNATIONAL MARlrIMI:-TAAINlNGCENTRE . 36

BASIC HYDRAULIC WORKSHOP RevO.O July 03 DIRECT ACTING SOLENOID VALVES COIL Pl.ASTlC CASE Figure: A direct-acting solenoid valve is one where the solenoid armature is dir ectly linked to the spool and provides the necessary push or pull "muscle" for s hifting it. In this single solenoid valve the spool is driven in one direction b y the solenoid force and in the other by spring action after the solenoid is dee nergized. Porting through the valve when deenergized and energized is shown by t he left and right blocks respectively of the symbol. This is the same as for an way valve. The valves naturall) discharge path valves these d out individually, simplify plumbin internally and,' connection,T TUBE FlUID Maximu size. Th electricall aximum s both LAND AREAS PWNGER PULLED IN INTERNATIONALMARITIMETRAINING CENTRE 37

BASIC HYDRAULIC WORKSHOP RevO.O July 03 l , 1 1 PRESSURE CONTROL VALVES These valves perform functions such as limiting maximum system pressure or regul ating reduced pressure in certain sections of the circuit and other functions wh erein tbteir actuation is a result of a change in operating pressure. f t 1 i f f t I I 4. 5. 8. Unloadingvalve usea"t(:jfcsaveTtpOWer unloading the by pump or pumps when large flows are not r equired ( otherwise the extra oil will go over the relief valve at high pressure ). o.G-4l~ ~~lN INTERN~NAL {~ p~\j~ ~ . J~WJ1 ~~ ~ 38 l~ ~~ MARITIME TRAINING CENTRE

BASIC HYDRAULIC WORKSHOP RevO.O July 03 PRESSURE CONTROL VALVES L--, 4. and can be adjusted. 3. Spring tension determines setting... -..' ~ 2. When pressure here Is less than valve setting, valve remains closed. INLET (FROM PUMP) 5. When valve setting Is reached, pump flow Is directed to tank.

~ ~ (J tJ :J::: ~ ~ ~ ~ ~ ~ '"6 /" ~It> c " f '\ ~ ~ ,",~-~ , '--' , , , , , , ', ~_J. : w IllUSTRATION OF A COUNTERBALANCEVALVE CIRCUIT . A counterbalancevalve 'C' is usedwhen there is a tendencyof the hangingloadW to causethe actuatorto 'creep' due to slight leakage at the spool of the direction control valve. This can also I:>e achievedwith a pilot operatedcheckvalve in placeof the counte rbalance valve. ::tI ~ ~ c ~ ~ c .....

BASIC HYDRAULIC WORKSHOP RevO.O July 03 General description These modules provide pilot operated check functions in one or both service lines (A and B), the pilot supply coming from opposite service l ine to that in which the check acts. When closed, the check prevents flow from t he actuator port to which it is externally connected. The construction of a dual check module is shown below: 2. F p T. -. 8 A

BASIC HYDRAULIC WORKSHOP RevO.O July 03 ~ ~ A. LOWERING CYLINDER B. RAISING CYLINDER Counterbalance valve. Spool Is held wide open. (No restriction to motor exhaust.) Low pressure here when directional valve Is centered. \ \ " ". Pressure created here equall that required to 11ft spool allowing exhaust flow. (Braking force.) Remote control pressure Is directly under spool. (Large area.) A. ACCELERATION OR CONSTANT SPEED Brake valve. B. BRAKING

BASIC HYDRAULIC WORKSHOP RevO.O July 03 COUNTERBALANCE VALVE ~ ~ t opens to permit free When the cylinder is be e valve can be internally flow for returning the cylin drained. In the lowering position, when the valve must be op en, its secondary port is connected to tank. In the reverse condition, it does n ot matter tl:lat load pressure is effective in the drain passage, because the ch eek valve bypasses the spool. .

BASIC HYDRAULIC WORKSHOP RevO.O July 03 Pilot Operated Check Valves These valves act like conventional non-return valves (i.e. aloe flow in one dire ction only), but can be opened by pilot pressure to allow flow in the reverse di rection Being poppet type they are virtually leak-free when closed and are thus useful in preventing creep or inadvertent njpvement of an actuator. They may als o be used to prevent movement of an A1iuator if a hose fails. 0 Flow into port passes fl B B ~ \ L Z A. A z

BASIC HYDRAULIC WORKSHOP RevO.O July 03 FLOW CONTROL VALVES The function of these valves is to controlthe flowof oiland thus, the speed of t he actuators. They are normally fitted after the direction control valve to prev ent power loss. . Flow control valves are essential direction only and this direc1. thus care shou ld be t designed to control flow in one the body by an arrow & d correctly. 1. 2. 3. Since, Flow a L\P any change in ...thepressure drop across the I orifice of the flow control valve will result in change in flow. To prevent this , we have valves called Pressure compensated flow control valves.

BASIC HYDRA ULIC WORKSHOP RevO.O July 03 TYPES OF FLOW CONTROL A a METER IN .1\. -y M l\b!",.Our CIrcuit Ijf ~ BLEED-OFF CONTROL I >B BI"ed-Off Circuit INTERNATiONAL MARlfIME:fAAfNIN~ CENfRE 46

BASIC HYDRAULIC WORKSHOP RevO.O July 03 ACTUATORS These convert hydraulic energy into mechanical energy. There are two types of ac tuators: 1. Cylinders: these are linear hydraulic actuators. 2. Motors: these ar e rotary hydraulic actuators. CYLINDERS: There are various types of cylindl 1. Single acting 2. Spr. 3. Do 4. Do 5. Tan

('J ~ ~ ::J:: ~ ~ ~ ROD END HEAD ROD END PORT OPTIONAL AIR VENTS (FOR BLEEDING AIR FROM CYLINDER) PI STONSEALS CAP END HEAD TIE ROD CAP END PORT ?=s CUSHION COLLAR ~ ~ S5 BODY Typical cVll der construction. n ::tJ ~ c::. ~ ~ ~IJ

1. Exhaust flow passes freely out of cylinder until. . . 5. Check valve allows free flow to piston for extension. 2..Plunger enters cap.. . 4. Rate of deceleration is controlled by adjustable opening. / 3. Nowflowmust take restricted path causing the piston to decelerate. CYLINDER CUSHIONS - ROD RETRACTING INTERNATIONAL MARITIME TRAINING CENTRE 49

CYLINDER PORT CUSHION NOTE:Closingof the ADJUSTMENT cushionadjustment screw SCREW shouldbe don ewithcare. ,-;<;-'7.";<;',-,-,-, ':~~::::::::::'::::::::::::::::: :::':':':':':,:,;.:,:,:,:::,:,:,:,:,:,:,:.::""" ,-,-,-,-.-,-,-.-,-,'.-,'.-,-,',',-, :.::::::::::::::::::::::::::,:::::;::::::':::::::;:::::::::::::::::::::::::::::: ::::::: ,'., , . , , , , , , , , , : , , , , , ,', , , , , . . , , , , , , , , , , . . , , , . ::::::::::::::: .::;::::::::::: ,::;:::::::::::::::::::::::::::: , , , , , . , , , , , , , . , , , , . , , , , . . . , , , , , , , , , , , , , , , :::::::: :::::::: :::::::::: -,-,'. :::::::: , , , , , , , , , , ::::::::::::::::::::::::::::::::: , ,. :, " , ::: : :::::::::::::::::::: , , , , , , , , , , , , 0,:::::::::::::::::::: , ." 0. ",', 0 ,,."""" ,.,., ,.", ",., '0' ,""0"" ,',',',',',','.',',',',',',',',',','.'.',' ,',',',','.',',',',',',',,',',',',',',', , , 0' , , , , , , , , , , , , , , , , , . , . , , , , . , , , , , . , , :::::::::::::;:::::::::::::::::::',',',',',',' ,'::::::','. ',' " ,',',',',',', "',' ,', : :::::::::;:::: ,',::::::::::::: : :: :::::::: :::, ,,', ',',', '.',',' ,',',',',',',' ,',',', ., ,""",',' , , , , ,..""".."",., , , , , , , ,,.".".", , , , ,.""" , , , , ,,,,, , ,,,, ,,, ,,,,, ,,, ,'0',',',',',',',',',',',',';',',',',',',', ',',' ,',',' ,', ', ',' ,',',', ',' ,',',' ,',',' ,',' ,,,,,,,,,,,,,,,0,,,,,,,,.,.. ,.,.., ,,...0 ,,,,,..,,,,.. .,...,.. ,,,.. ,,,,,,,,,.,,," , , , , , , , , . .. ,, , .. , ,.. , .. , ,, , . . ,, .. , ,, ., , .. , .. , . .. . , , , , , , , , , , , , . , , " , , , , , , , , 0, , , , , , , , , , , , , , , , , , , , , ,. .. "U..'.'..'..' , ,'.','.'.','.'."', .. .. . ,.',.. . . , ...'.'. ,' ,0'.',"... ,'." . .. .. .. '-'-' '-',','.'.' , , , , . " , , , .. INTENSIFIEDRESSURE P Cylinder cushions-rodextending.

CONN~cr\NG p.OO v.I\NOOV'l pof{{S PistoN

BASIC HYDRAULIC WORKSHOP RevO.O July 03 ACCUMULATORS Since hydraulic fluids are essentially incompressible, they do not have"the abil ity to store power. Hydraulic accumulators store the potential energy that is in the incompressible fluid for subsequent conversion to useful work. Functions: 1. Pulsation damper and shock absorber: It dampens the pulsations pressure surge s can would this st Combl Safety failure. POW~j rea olerable levels. Also, heavy Ive in the system - this rs.~.bs:~f:;111&:cushion 2. 3. 4. 1. 2. 3. 4. The Note: Never open any componenllflliJlim71i'ltl'n::I@tne hydraulic ensuring that the accumulator fluid has been drained to tank. Other ways of reducing vibration: system before 1. - Clamp pipes at short intervals... 2. 3. If possible pump to have flexible hoses at suction at delivery ends for ab out 1/2 mtr. Motor and pump to be mounted on foundation using shock absorbers.

..... BASIC HYDRAULIC WORKSHOP RevO.O July 03 TYPES OF ACCUMULATORS Air /Vent Spring 1 1 Gas Port ~ i , ~ Pinon . Oil A Shelt ..' 'Oil Port A.BLADDER -.::= Oil Port B. SPRING LOADED C. WEIGHT LOADED D. DIAPHRAGM Types of Although types ar in popul Bladder between a valve 1 always rE and floats bag closes lesigned to g its life . Diaphragm A diaphragm se limited. The sc. Charging an On hydraulic system using a charging and gauging assembly to accumul ator used should be on hand for use of maintenance people. A pressure bottle of oil pumped (dry) nitrogen should also be on hand. The assembly may also contain a shut off valve between the gauge and bottle adapter so the assembly can be lef t attached to monitor gas pre-charge. All oil must be discharged before checking or adjusting precharge pressure. INTERNATIONAL MARITIME TRAINING CENTRE device. Rubber laximum size is harged. ~ Thread to Fit Gas Port on Ac:c:umu~tor

Threld to Fit Preuure Sonles Adapter for Bo~.. Wit:L.H7 1m 54 CHARGING AND GAGUING ASSEMBLY

ACCUMULATOR START -~ THE ACCUMULATOR CONSISTS OF TWO COMPARTMENTS ONE THE BAG WHICH ... CONTAINS THE GAS (NITrOGEN) THE OTHER A STEEL SHELL INTO WHICH THE FLUID IS PUMPED -+ THE GAS IN THE BAG PRODUCES A RESISTANCE TO THE PUMP FLOW THERE BY CREATING PRES SURE TO ENSURE THE B~G DOES NOT EXTRUDE AND BURST, A VALVE IS FITTED TO ELIMINATE THI S SO THAT THE ENERGY CAN BE STORED IN THE ACCUMULATOR l . L WHEN FULLY DISCHARGED THE GAS IN THE BAG INFLATES IT TO FILL THE ENTIRE STEEL SH ELL

ACCUMULATORS Function A hydraulic accumulator is a vessel in which a fluid may be kept under pressure. When liquid is supplied to the accumulator through the oil valve, the rubber bag is compressed, and the pressure of the oil mounts. When the oil press ure drops, the rubber bag expands, and the accumulator delivers oil to the hydra ulic system into which it is connected. Hydraulic Ac Components The hydraulic co mponents 1. A stel 2. Arul the 3. A bj t 4. 2. There is a slit or tear some 10-4 0 cm from the bottom end of the bag. Causes: After installing the bag it has bee n charged too rapidly. During installation, tre entire oil valve must be introdu ced into the accumulator. The nether part of the bag may then be forced upwards or even folded on itself. With a high charging rate, the bag is not 'me to assum e its correct shape, but is 'ned in its lower peripheral parts. own the middle n to the g of the bag must slow rate in order to open up into its e is tightened alve proper bag will be of the bag ,hen cause bag. e vented! Malfun Faulty relative. compon malfuncti and may installation ~ surveillance Typical dam 1. The I at a charc ~, Cause: T to nothing (through diffu sl years of operation or because 0 charging valve or through failure to check th e tightness of the valve after charging). The bag has been compressed by the hyd raulic circuit pressure until the upper part of the bag has folded itself over t he charging valve 2 .:I and been punctured by it. . . There is a slit or tear some 10-40 cm from the bottom end of the bag. HYDRAULIC PRESSURE ACCUMULATOR

BASIC HYDRA vue WORKSHOP RevO.O July 03 ACCUMULATORS N.B. Check the charging pressure of the bag every year (approx. 1000-hour interv als) and also when replacing the oil cooler in the system. Insufficient gas pres sure in the bag may cause the following kinds of damage: 1. The rubber bag in th e accumulator i compressed by the hydraulic circ pressure, and is torn by the ch arging val A new accumulator must be installed. 2. Hydraulic pumps and motors do wn. They require a pressurl 3. Excessj eventua.~, '!fuP" too fa(~)f operati ' To charge a h' of Fig. HAGGLUN bar (600 k 2 meters) W24 co bottle. W24/14 Chargin (N2). (Ail 1. C ac , 9. Close the nitrogen bottle shut-oft valve tightly 10. Ope n the discharge valve of the 3-way valve to vent the pressure in the filling hos e to the outside air. 11. Return the reducing valve to zero. 12. Remove the char ging equipment from the nitrogen bottle and from the accumulator. 13. Use a soap solution in water to check that e accumulator charging valve is perfectly d saf ety screw ag to the f filling, and erator. cessary to fit bottle. 2. 3. 4. 5. 6. 7. 8. scn oper tight. . Connei nitroge reducin Open until t Open t Adjust theieducing v charging pressure (see table obtained. Turn the 3-way valve filling screw cloc kwise, but not too tightly as this may damage the accumulator chargingvalve. Fil l the accumulator bag with nitrogen. Check the nitrogen pressure in the bag when the temperature and pressure of the gas have stabilized. When the correct press ure has been obtained, back out the filling screw of the 3-way valve. Connector nitrogen W24 for' bottle , . NITROGEN HARGINGQUIPMENT C E INTERNATIONALMARITIMETRAINING CI:I\I"TRE 57

Maintenance tip: watch gage to monitor precharge pressure The precharge pressure in a bladder should be checked at least once in a month a ccording to one accumulator manufacturer. This simple preventive maintenance act ion will assure consistent flow to the cirGuit and extended bladder life. The co nventional way to check prechar! all pressures from hydraulic circuit. Then inst all a gage head assembly, the precharge pressure fl the next a to shut of the pu mp and discharge cap the accumulator charge value, Ive with its tee handle. If c edures and go to For multiple-accumulatorcircuitsln'~'ge~iII indicate the condition of the lowest precharge pressure. If that pressure shows less than required, checks of each i ndividualaccumulatorwill be necessary.

SAFETY AND PRECAUTIONS BEWARE OF : 1. leaks : can make the afe}rSlippery. : can constitute a ~pour and fire hazard. : leaki

RELIEVING SYSTEM PRESSURE Pressure may be due to external loads or forces. Eliminate them. . Lower or move all parts to the rest, 2r untensioned position before shutting the system down. ay be counterbalancing loads. . Carefully open adjustable valves t an be reset) . (Note the setting first, so the valv . Jack or wedge the load ulic pressure me chanically, if n Pressure or charge . Se . We di . Eve .

LOWER OR MECHANICALLY SECURE ALL SUSPENDED LOADS ISOLATE THE ELECTRICAL POWER SUPPLY SAFETY PROCEDURE FOR SHUTTING DOWN MACHINES

BASIC HYDRAULIC WORKSHOP SYSTEM INSPECTION AND MAINTENANCE CLEANING OF HYDRAULIC FLUIDS RevO.O July 03 How clean should the Hyd. Fluid be ? Hydraulicfluid serves as a medium for trans mittingforce from one place to another. It must quicklyreflectchanges in force's directionand magnitude. To meet these needs, a fluidmust have: . enough viscosi ty to efficientlytransmit fo~ce, prevent cavitation and guard against overheatin g m components sufficientlubricatingcapabilityto protect and 60 deg.C - ideal ra nge is 50-55 . temperature between the fluid's pour deg.C anti-wear protection,i fne oxidatio . adequ . . . . . . . , good d rust inh resistal comp .. Res Freqi Envir Equipt Onlyn Whydo Results . . . 10% 5% - u 10% 5%inade 70% poo WARNING- Before breaking a cTrc'f:iif~r:m~6ti."*m'*aKepower is off and system su re pressure is released. Lower all vertical cylinders and discharge accumulators. CAUTION - Absolute cleanliness is essential when working on a hydraulic system. The presence of dirt and foreign materials in a system can result in serious dam age or inadequate operation. NOTE - Discard and replace all '0' rings, gaskets and back up rings removed duri ng disassembly. INTERNATIONAL MARfTrri/f~iAAINING CENTRE 62