1.0 Basic Hydraulics1 PDF

BASIC & VRM HYDRAULICS TRAINING
Venue : Fern Residency, Udaipur

Date: 12-13/9/2017 © 2013 FLSmidth. All Rights Reserved
Contents
12.09.2017 13.09.2017
 Introduction to oil  Atox mill Hydraulics

Hydraulics  OK mill Hydraulics
 Basics symbols  OK Ver3 Mill Hydraulics
 Energy Converters-Pumps &  FRM Hydraulics
Motors  Components Demo
 Control Elements-Valves  Mill Hydraulic System(Other than FLS)
 Proportional Technology  Roller lubrication -Atox & Ok
 Hydraulic Cylinders mill
 Accessories  MAAG Gear lubrication
 Basic Circuits  Hydraulic Roller Press(HRP)
 Stacker Reclaimer  Ball Mill Lubrication Systems
 SFC ,CB Cooler ,Kiln-HTD  Troubleshooting Tips
 Other Cooler drive circuits  Hydraulic Safety
© 2013 FLSmidth. All Rights Reserved
1
Definition of Hydraulics
OLD DEFINITION:
In Greek words, hydra means water, so study is called hydraulics.
TECHNICAL DEFINITION:
Transmission & control

of
forces & movements
by means of fluids
is called hydraulics
We use the ability of fluids to transmit power or to perform a task

or –if we refer the task to a unit of time- a function, by conversion into various forms of
power.
Transfer of Energy in Hydraulic circuit
2
Atox Mill Hydraulic Tensioning Circuit
• Rollers Up
• Rollers Down Pipe Connections PT
• Grinding
A B Bx
Bx Block
M-BLOCK PT
Hydraulic Cylinder With Accumulators

PT Water Valve PT
Pumping Unit
Piston Pump Conditioning Pump
PT Transmitter for GR Pr & N2 Pr

3 Cylinders with each 3 No's Accumulators Mounted
OK Mill Ver3 Hydraulic Circuit
• Rollers Up
• Rollers Down
• Grinding Pipe Layout
• Quick lift
Function
VALVE BLOCK
Cylinder with
Accumulators
Pressure Indicators
Cooling /filtration
TANK
Vane Pump Conditioning Pump
3
CB-COOLER CIRCUIT
Hydraulic. cylinder
Closed loop Pump

Accumulator
A
Pr Line Filter
Booster E-MOTOR
pump
B
Oil tank
Booster Relief valve
Flushing Valve
A Pressure in Port A-Forward , Pressure in Port B-Reverse
HRP- Hydraulic Circuit
Extractor Circuit
Hydraulic
Cylinder
Poppet Slip-
in Cartridge
DC valve
Piston Pump
Conditioning Pump
4
Atox Mill Lubrication Pump Station
Supply Lines to 3 Rollers Breather /Overflow lines Return lines
Sight glasses
Duplex filter
Relief valve(12 Bar)
Cooler
Water sol. Valve
OIL TANK
Filter
Feed pumps(3)
Return Pumps(3)
Conditioning pump
Loesche Mill Hydraulic Circuit

Rollers Up
Rollers Down
Grinding
Pressure Reduce Op Pr
by-pass DCV INC Counterbalance pr Regeneration
valve
Dec Lowering
Filter coun
Relief @140 bar ter
pr
Gear Pump
Hydraulic Cylinder with

Accumulators
5
HYDAC PU(Pfieffer) for Mill Tensioning
System
Hydraulic Cylinder
with Accumulators
Flow Divider
Dc valves
Dc valves
Dc valves
Filter
Relief valves
Filter
Oil Tank
Pump
Oil Conditioning unit
Raw Mill (Kawasaki)

Hydraulic
Cylinder(3)
Swing-out
Circuit
Accumulators
DC Valve Pilot Op Check

Valve(5)
Unloading PRV
Pilot DC
valve(4)
Constant Disp.
Piston Pump
6
Energy converters
Control elements
7
Modulating valves
Accessories
8
Comparison of various energy transmission
methods
Features of hydraulics
9
Hydraulic Circuit(Pictorial View)
Simple hydraulic circuit (Symbolic

method of presentation)
Cylinder
FCV
LDCV
NRV
PRV Filter
Pump
10
Hydraulic Symbols
Lines
Hydraulic Line Pilot Line or Drain Flexible Line
Connecting Lines Passing Lines
Pipe
Connection Plug
Tank Line to Tank Equipment Enclosure
11
Pumps
Fixed Displacement Pump
Bi-directional Pump
Pump with Motor
Tandem Pump
Variable Displacement Pump
Pressure Compensated Pumps
Pressure Compensated Pump
Pressure Compensated
Axial Piston Pump
12
Hydraulic Actuators
Linear Actuators Rotary Actuators
Single Acting Hydraulic

Cylinder Motor
Double Acting Bi-Directional

Cylinder Motor
Double Rod Variable

Cylinder Displacement
Motor
Tandem
Cylinder
Check Valves
Check Valve
Check Valve, Spring Biased
Shuttle Check Valve
Pilot Operated Check

Valve, Pilot to Open
Pilot Operated Check

Valve, Pilot to Close
13
Flow Controls
Orifice Plate
Flow Restriction, Fixed
Flow Control Valve
Flow Control Valve, Temperature

and Pressure Compensated
Flow Control Valve with

Reverse Free Flow Check
Pressure Control Valves
Pressure Relief Valve
Unloading Valve
Pressure Reducing Valve
14
Directional Valves 4-Way, 2-Position
4-Way, 2 Position Valve
Manually Operated,
Spring Return
Manually Operated
with Detent
Solenoid Operated
Methods of Operation
Manual Mechanical Hydraulic

Operated
Lever Detent Pneumatic
Solenoid
Pushbutton Spring Controlled
Pilot
operated
Pedal Solenoid Servo

Pilot
15
Directional Valves, 4-Way, 3-Position
Closed Center
Open Center
Tandem Center
Float Center
Proportional Valves
Proportional Valve
Proportional Valve,
Solenoid Operated
Pilot Operated
Proportional Valve
Proportional Valve
with LVDT Feedback
16
Filters
Filter, Strainer or Breather
Filter with Bypass,

Differential Pressure Switch
and Gage
Tandem Filter
Heat Exchangers
Cooler
Air Cooler
Water Cooler
Heater
17
Accumulators
Accumulator, Weight Loaded
Accumulator, Spring Loaded
Accumulator, Gas Charged

(Hydro-pneumatic Accumulator)
Hydraulic Symbols
Tank Open loop Pump( Fixed Displacement) Open loop Pump(Variable disp)
Reservoir
Reservoir with
Strainer
DC Valve (2/2) DC Valve(3position,4 way)

Filter with NRV(Return line)
18
Hydraulic Symbols
Pumps and Motors
Function
Pump: Conversion of Mechanical Energy to Hydraulic Energy.
Hydraulic Motor: Conversion of Hydraulic Energy in to rotary

movement(i.e, its transmit a torque) .
Hydraulic Cylinder: Conversion of Hydraulic Energy into useful

Mechanical energy in the form of force,work,power.
19
Basic components of Hydraulics system
 Tank
 Pumps(Vane,gear,piston etc)
 Control Elements(Directional Control,Pressure

Relief/reducing/sequence,Prop DC,Check, etc)
 Actuators(Linear Motion)& Hydro Motors(Rotary Motion)
 Accessories' like Pressure gauge,slight glass,temp indicators,heat

exchanger ,accumulators
Pascal’s Law
Pressure exerted by a confined fluid acts

undiminished equally in all directions.
20
Pressure intensification in cylinders
Resistance to Flow Creates Pressure
25 PSI
Figure 1
The pipe is open at the end allowing fluid to flow out
freely. The only pressure in the system comes from the
pipe’s fluid friction resistance.
21
50 PSI
A cylinder is connected to the pipe. Pressure increases

slightly due to the piston bore friction and the fluid
turbulence as it enters the cylinder.
1050 PSI
Load
A load is applied and the pressure in the system

increases by 1000 PSI to 1050 PSI.
22
Design & Selection Criteria
F
P =
A
Velocity
 Pressure line VELOCITY 3-4 m/s (for pressure up to 100

bar) 4-8 m/s (for pressure up to 100-315 bar)
 Return line 2 m/s
 Suction line 0.5-0.8 m/s for negative suction 0.8-1.5 m/s

for positive suction
F
P =
A
23
Applications :Products and solutions
OPEN LOOP:
 Boom luffing
 Operator cabin
 Wagon clamping
 HRB System ATOX
 Mill System/Cooler drives MILL
 Coupler release
 Door opening
 Kiln HTD/Thrust Rollers
 Material Gates/Hot Disc
CLOSED LOOP:
 Cooler drive
 Bucket wheel drive

 Slewing drive
SF
 Wagon tippling drive Cooler
 Side arm charger drive
 Paddle feeder & travel drive
 Chain conveyor feeder drive
Open loop system Vs. Closed loop system
Open loop system Closed loop system

Cylinders of equal displacement.
Cylinders of unequal
Quick response time.
displacement.
Operational feed back mechanism
Moderate response time.
with Position sensor & Proportional
No operational feed back
DC valve
mechanism.
FLSmidth 2007 all rights reserved. © 2013 FLSmidth. All Rights Reserved
24
HYDRAULIC PUMPS
 Positive Displacement Pump: The output volume per

revolution does not change with pump speed or
pressure. Internal clearances are minimal. Industrial
hydraulic pumps are normally positive displacement.
External Gear Pump
25
Gear Pump Principle
External Gear Pump
Drive gear
Drive Shaft
Gear Chamber Driven gear
Pair of Gears run with small radial & axial play as to give virtually sealed condition
of oil volume. By means of the gear driven in the direction of arrow, the mating
gears move the second gear in opposite direction.
26
Gear Pump in a Atox Mill Circuit
Filter
Gear Pump Function: Oil

Filling, Emptying ,
Oil Cooler Conditioning & Cooling
Crescent Seal Gear Pump
27
Internal gear pump (Crescent seal
variety)
Internal Gear Pump in-built in Closed

loop Drive Piston Pump(4)
Internal
Gear Pump
28
Fixed disp.Vane pump
Cartridge Kits
Camring
Balanced Cartridge
Plate/Port Kit
Plates
Dowel
Pins Rotor
with
Vanes
29
Vane Pumps in OK Mill (FLS) and China
VRM
CHINA VRM
Ver3-OK MILL
Variable displacement Vane pump
30
Piston Pump Principle
31
Piston and Cylinder Block
32
Swash Plate
Axial Piston Bent Axis Unit ( Variable

disp. Principle)
33
Axial piston, Bent axis, Fixed disp. Unit
Fixed vs. Variable Displacement
Fixed Displacement Pump

The volume of fluid coming out of the pump in each
revolution is fixed.
Variable Displacement Pump

The volume of fluid coming out of the pump in each
revolution can be varied.
34
Axial Piston, Variable Disp., Bent axis
Min flow
setting
Max flow
setting
Axial Piston Pumps
CLOSED
LOOP
OPEN
LOOP
35
Axial piston unit – Swash plate
principle
Axial Piston, variable, disp., Type

A10VS0 (Rexroth)
MAXIMUM ANGLE ≈ 15°
Flow
Setting
Pump
Pressure
Setting
36
Axial Piston Pump
Piston
Swashplate
Control
Piston
Cylinder
Barrel
Valve Plate
Input
Shaft
Pressure
Swashplate Compensation
Control Piston
Only the input shaft, cylinder barrel and pistons rotate. The swash plate
and valve plate do not rotate.
Minimum temp to start is 25 deg C.
DFR Controller
Flow control (Δp - base)

axis
Pressure control
axis
P A T
37
Pressure Compensator
(Presure Limiter)
Q
Q0
QMAX
PRESSURE
LIMIT
Pressure Compensator
(Presure Limiter)
Q
PMAX
Q0
QMAX
PMAX
38
Drain Connection
Piston Pump
drain
should be
directly
connecting to
tank
Axial Piston Pump - Kiln HTD
Drain
Motor
Piston Pump
Pressure Compensator set@75 bar
39
Axial Piston Pump in ATOX MILL
Drain
Priming point
Piston Pump
Delivery
Closed Loop Pumps
Closed loop pumps are variable

displacement pumps used in hydrostatic
drives where fluid coming back from the
actuator returns to the pump inlet instead
of to a tank. They may include a built-in
booster pump to make up for system
internal leakage.
40
Principle – Variable disp axial piston pump
A4VG Closed
circuit
Closed loop Piston Pump A4VG series
Drain T1 & Cut Off Pr Relief Booster Pump

Prop DCV
R Port Dfes00.zip
Port B & A
Pump
shaft High Pr Relief
valves(A & B)
280/385 bar
Booster Relief
valve(35 Bar)
Drain T2
Mechanical centering adjustment
41
Gold Cup Pump Series
In built -Booster Pump
Valve Block
Drain
Pump
shaft
Angle Sensor
Port B & A
Close loop PUMP A4VG – Side view Hydraulic

.
Main Pump-The movement of a drive is controlled by a prop

valve , which is able to deliver oil flow in two directions.
Booster Oil Pump- the booster pump ensures that a sufficient

oil volume is constantly maintained on the suction side of the
main pump
42
Closed loop pump with Prop DCV &
Flushing Valve
Prop
DCV Flushing
valve
16 bar
Piston Shoe Lubrication
43
Radial piston pump
Radial piston pumps are used

in ball mill (Pre-Jacking) as
well as MAAG Gear thrust
pad lubrication
Pump Calculation
 Piston Pump-45
cc/rev
 Motor- 30 KW ,1500
rpm
 Pump Flow-65 lpm
44
 HYDRAULIC MOTOR
Hydraulic Motors
Hydraulic motors operate similar to their pump
counterparts, except in reverse: fluid entering the
motor causes the motor shaft to turn.
45
Radial Piston Motor- Bucket Wheel Reclaimer
Drain Port
Pressure
Ports A & C
A radial piston motor is often used in applications requiring a very

high starting torque, as on this apron conveyor feeding a primary
crusher .
Only one Drive(Bucket Wheel)
46
Axial piston unit – Bent axis design
( Fixed Motor)
Vane Motor
Torque Planetary
Arm Reducer
Vane
Motor
This 40 horsepower hydraulic vane motor, mounted on a planetary

reducer, is used to rotate the rolls of a clinker breaker. Note the
motor’s compact size.
47
Roll Crusher Schematic
Hydro Motor
DC Valve
Piston Pump
Product Overview
48
CONTROL VALVES:
Control valves used in controlling the fluid pressure, flow and direction.
CONTROL
VALVES
PRESSURE FLOW DIRECTION
M/s DPCL- O & M site 11

4
Hydraulic Controls
 Direction control valves

 Pressure control valves
 Proportional DC valves
 Flow control valves
 Check valves & modular concept valve
49
Pressure Control Valves
Adjustable Relief
Closed Set @
700 psi
P=500 psi P=0 psi
Working principle-Direct Operated Relief

Valve.
50
Adjustable Relief
Closed Set @
250 bar
P=100 Bar P=0 psi
Pressure
Tank
Pressure Relief valve in operation
51
Manual
Adjustment
Pressure relief valves are safety devices that protect the system from
overpressure. When the valve’s setting is exceeded, fluid is dumped
back to tank.
Sub-plate
Sub-plate mounting makes a neat installation, easy to service and less

prone to leaks.
52
Pilot operated PRV. - DB
Safety Relief Valves – Boom Cylinder
Safety Relief Valve
53
Pilot Op PRV,with direct unloading -
DBW
Unloading
stage
Pilot Stage
Main Stage
Unloading Pressure Relief –Atox Mill (Y03)
Unloading Relief
valve (57 set at 210
bar)- Electrical
Unloading
Relief
valve-
Hydraulic

5
54
Principle pressure reducing valve
Directional Control Valves
55
4-Way Directional Valve
Directional
Valve
Valve
Spool
T A P B T A P B
Cylinder
High Pressure from Pump (P)

Low Pressure to Tank (T)
With the valve spool pushed to the left, fluid flows from P to A and B to
T. With the spool to the right, flow is from P to B and A to T.
56
Directional Control Valve Hand
Operated
Detent
Shifting the lever moves the spool, changing the direction of flow. This
valve has a detent, which keeps the spool in position after the handle is
released
DC Valve, Mech.Op. 4/3 Way, Size 10
57
Directional Valves -
Supply Sources; 24 VDC

Spring Offset 110 VAC
A B
230 VAC
P T
T B P A
Most commonly used ; 24VDC for solenoid coil as well as
Figure 8.14 Two-Position, Four-Way Valve is Spring Offset
Amplifier card
COPYRIGHT C (1999) VICKERS, INCORPORATED
Solenoid Operated DC valve
58
Solenoid Operated Directional Valve
Coil
Armature
A solenoid is an electromagnet. When energized, the magnet pulls the

armature in and the spool shifts position.
Simple Hydraulic Circuit in Operation
Load
A B
Solenoid
De-energized
Cylinder Movement
P T
P- Pressure port
High Pressure
T- Tank Port Low Pressure
A/B-Actautor Port
59
Directional Valve Operation
Load
A B
Solenoid
Energized
Cylinder Movement
P T
High Pressure
Low Pressure

2
3-Position Directional Control Valve
This valve’s spool has 3 positions: left, right and center. When neither solenoid
is energized, the springs center the spool. Different spools are available for
different center position functions (open center, closed center, tandem center,
float center).
60
Directional Control Valve
Solenoid Operated
“B” Solenoid
Connection Coil
Box
“A” Solenoid
Coil
Spool
Manual
Override
Centering
Spring
DC Valve(Poppet type)
61
DC Valve, Elect Op, 4/2 Way, Size 10
DC VALVE SYMBOLIC REPRESENTATION

Blocked Center
Directional Control Solenoid Operated H-Center (all open)
Valve - Non-energized
Directional Control
Valve - Energized Blocked Center
Hand Operated P-T Center
62
Frequently used types sliding spools
(Rexroth Denomination)
Pilot Operated Directional Valve
Pilot Pilot Valve

Passageway
Main Valve
When pressurized fluid from the pilot valve is brought to the main
valve’s end chamber, the spool is shifted.
63
Pilot. DCV, 4/3 Way, W/o. Pilot choke
Solenoids can operate valves up to ½” in size
Pilot Valve For larger sizes, a small

pilot valve is piggy-
backed onto a larger,
hydraulically operated
Main Valve main valve, with the
output of the pilot valve
directed to the spool of
the main valve.
Pilot DCV, 4/3 Way, W/o. Pilot choke
Main Valve
Pilot DCV
64
Pilot operated DCV. With Meter-In Pilot choke
Pilot Valve
Throttle valve
Main Valve Body
Pilot.Op. DCV. With Meter-Out Pilot

choke
65
DC Valve. Pneumatically operated
Flow Control Valves
Adjustable Valve
(i.e. needle valve)
66
Needle Flow Control Valve
Most hydraulic flow control valves are needle valves. They are used to
adjust the speed of actuators.
Needle Flow Control Valve
Inline Mounting Manifold Mounting
67
Simple Throttle valve
Pressure and Temperature Compensated

Flow Control Valve
Flow rate depends on:
 Size of Orifice
 Upstream Pressure
 Downstream Pressure
 Fluid Viscosity (Temperature)
Flow control valves are often pressure and temperature compensated to

maintain the set flow rate even as upstream or downstream system
pressures change, and as fluid temperatures change.
68
Viscosity compensated throttle
Flow control valve in system(Meter-

Out Circuit)
69
Ball Valve
Ball valves are either fully open or fully closed and are used to isolate parts of a
hydraulic system. They should not be used to regulate flow. They are normally
manually operated.
Check Valves
70
Check Valve
Poppet Spring
B A
Flow Direction
A check valve allows flow in one direction only. The fluid unseats the
poppet when flowing from B to A, and forces the poppet closed when
flowing from A to B.
Check Valve
Inline Mounting Manifold Mounting
A check valve allows flow in one direction only.
71
In-line mounting check valve
PILOT OPERATED CHECK VALVE: Putting pressure on the X-port will force the
poppet open in both directions and flow is from A to B or B to A. Without
pressure on the X port Flow is from A to B only and B to A is blocked. Internal
drain & external drain with inline & sub plate mountings are available.
72
POCV In operation
POC valve with external drain
73
Double check valve modular design
Luffing Circuit- Hydraulic Valves
SPARE
Valve
Shuttle
stand
valve
Pressure
reducing
valve(160
bar)
Prop. DC
valve
Unloading
Pressure Relief
Pressure valve(210Bar)
switch

1
74
Load Holding Valve (FD)
Load holding circuit using Check-Q-

Meter(FD- Valve)
FD Valve
75
Load holding circuit
2- COUNTER BALANCE VALVE
Sandwich Mounting
Solenoid Operated
Directional Valve
Check Valve
Pressure Relief
Valve
Manual Valve
Manifold
Directional valves are frequently mounted in a stacked “sandwich”
configuration together with other valves to simplify the piping.
76
Manifold Assembly
Cartridge Valves
77
Logic cartridges (Various sizes)
Logic element symbol as per

DIN24342
78
Cartridge Valve
Control
Cover
Bushing
X
Spring
B
Cartridge
Element
The valve opens and flow is from A to B, or B to A, whenever the

forces pushing up on the cartridge element exceed the forces
pushing down.
Logic cartridge spares
Spring
Insert
Cartridge
Spool
79
Logic Cartridges in Mill Valve Block
The valve block contains logic valves, which control the oil flow to
and from the accumulators.
Logic Valves
Cartridge Check Valve
The pressure above the cartridge

element, and the force of the spring,
hold the valve closed. There is no
flow from B to A. However, with
sufficient pump pressure, the valve
will open and fluid will flow from A
to B.
80
Cartridge Flow Control Valve
Stroke
Limiter
By physically limiting the movement of the cartridge element with a

stroke limiter, the size of the opening A to B (and therefore the flow rate),
can be controlled.
Cartridge Pressure Relief Valve
Pilot Valve
Pilot
Passageway Y
(Connected
to Line A) Drain to Tank
B
A
The adjustable pilot valve opens when the preset pressure in line A is
reached. The pressure above the cartridge valve is drained to tank and the
valve opens.
81
Pilot
Passageway
(connected
to Line A) Pilot Valve
Drain to Tank
A
The adjustable pilot valve opens when the preset pressure in line A is
reached. The pressure above the cartridge valve is drained to tank and the
valve opens.
Solenoid
Operated
Directional
Valve
Control
Cover
Cartridge
Element
Adjustable Pilot Valve
This pressure relief valve has an optional solenoid

operated directional valve which allows electrical
unloading (opening).
82
Logic Valve Features
 Space Saving
 Zero Leakage
 Greater Contamination
resistance
 More efficient operation
 Elimination of Ext.leaks
 Improved reliability
 Low installation costs
 System design flexibility
Signal flow diagram - Proportional

technology
83
On Board Electronic On Board Electronic
with
Fieldbus connection
Analogue Digital CANopen / ProfiBus
Analogue
Amplifier Amplifier
Module amplifier Integrated analogue Integrated digital
Top hat rail valve electronic valve electronic
Euro format Euro format
Proportional Valve
Electronics
Variable
Solenoid
Notched
Spool
A proportional valve controls both flow direction and flow rate. The spool can be
moved to any position in its travel, not just to one end or the other as with a
normal directional valve.
84
Pilot Op. Prop. DC Vlv. – W/o.
feedback
Pilot Operated Proportional Valve
Pilot Valve
Main Valve
LVDT
Larger valves are controlled with a pilot valve. The LVDT senses the
position of the main valve’s spool. The distance the spool is moved
determines the flow rate.
85
Pump control card
Typical example of an amplifier card
86
Force controlled Prop Solenoid
Force ( 0 - 100 % )
Newton
Command
value
Current solenoid Volt
(0 - 100 %)
( 0 - 100 % )
Ampere´
Amplifier
Stroke controlled proportional solenoid
Stroke ( mm )
0 - 100%
Position- Command value0 - 100%

transducer Correcting
variable
0 - 100%
Amplifier Potentiometer
0 - 100%
Actual value
87
How to measure Voltage, Current
Ramp Time (Definition + Sketch)
88
Hydraulic cylinders - Principles
Hydraulic Cylinder
Piston Seals
Cap End Rod End
Rod Cartridge
Rod
Wiper
Seal
Port Piston Rod Seal
Piston seal wear will cause internal leakage, requiring the pump to start
frequently in order to build up the lost pressure. Rod seal wear will show up as
external leakage.
89
Cylinder Performance Dimensions
Stroke
Rod
Diameter
Bore
Cylinder performance is defined by its bore, stroke and

rod diameter.
Cylinder Force
Rod Extending Rod Retracting
Effective Area Effective Area
Force = Pressure x Effective Area
Pounds = PSI x In2
The force is greater at the same pressure when the rod extends since the
effective area is greater.
90
Heavy Duty Mill Cylinder
Tie Rod Cylinder
91
Cylinder Cushioning
Cushioning Plungers
Port A Port B
Needle
Valves
Some cylinders have cushions to slow down the piston at the ends of it’s
stroke to avoid mechanical shock. The degree of cushioning is adjusted with
the needle valve.
Cylinder Seals
92
Piston Seals
Seals
Wear
Band
Defective piston seals will cause internal leakage, resulting in slower cylinder
operation, drifting under load and excessive demand on the system’s pump. Bore
damage can also occur.
 HYDRAULIC ACCESSORIES
93
Gas Charged Accumulator
Gas-filled
Bladder
Hydraulic
Fluid
An accumulator is used as a “spring” in a hydraulic system.
Accumulators
 A type of power storage devices,

 functioning as a temporal storage
tank
of fluid energy to provide or absorb
momentary flow.
Functions of Accumulators:
 Energy storage
 Pulsation absorption
 Shock cushioning
 Supplementing pump flow
 Maintaining pressure
 Fluid dispensing
94
Various accumulator concepts
Bladder Accumulator (Various stages

of operation)
95
Bladder Accumulator
Nitrogen
Hydraulic
Fluid
Hydraulic Pressure Hydraulic Working Hydraulic Working

Below Precharge Pressure at Pressure at
Pressure Minimum Maximum
When hydraulic pressure increases fluid flows into the accumulator.
When hydraulic pressure decreases, fluid flows back into the system.
Accumulator Charging Kit
The pressure reducer is needed if the nitrogen bottle

pressure is greater than the accumulator maximum working
pressure.
96
Accumulator application – Leak oil
compensation
Accumulator application – Pulsation

damping for pumps
97
Accumulator safety block
Bladder Accumulator Charge Limits
Maximum charge = 90% of system hydraulic pressure

Minimum charge = 25% of system hydraulic pressure
 Above 90% pre-charge, the bladder can become
damaged from chafing on the anti-extrusion valve.
 Below 25% precharge, the bladder can become damaged
from folding and collapsing. At very low recharge a
pinhole puncture can form at the gas valve.
 It is important to review the accumulator pressure
whenever changes are made to the system pressure.
FLS recommended to charge N2 pressure minimum of 50% &

Max of 80% of operating Pressure
98
Pressure Switch
Pressure switch- The function of pressure switch is to check that a sufficient
pressure is maintained in the system or may trip the system when set pressure
is reached
.
Pressure switch in a SF Cooler Drive
 Pump may trip at booster pressure less than 20 bar
Pressure
switch
99
Pressure transducer & display device
Pressure Transmitter IN A SF Cooler drive:- To Indicate the actual

Pressure available in line in the form of analog signal(4-
20mA).Used in hydraulic circuit- For all drive -A & B line
Pressure transmitter
100
Fluid Conditioning
 Hydraulic Fluids
 Viscosity Control
 Contamination Control
 Sampling and Analysis
Functions of Hydraulic Fluids
 Power transmission
 Lubrication
 Cooling
 Sealing
101
Hydraulic Fluid Additives
 Anti-Wear (AW)
 Rust & Oxidation (R&O)
 Anti-Foaming
Viscosity
Definition
Viscosity is a liquid’s resistance to flow.
Viscosity is the most important characteristic of hydraulic

fluid. The fluid must be thin enough to flow easily through
the system, yet thick enough to form a good lubrication film.
102
Fluid Viscosity
Viscosity decreases with rise in temperature.
Viscosity Too High
 Fluid cannot flow into pump inlet, causing

cavitation and pump damage.
 Pump cannot push the fluid through the
piping, causing pump motor overload.
 High pressure drop and heat build-up due to
increased fluid friction in system.
 Fluid cannot penetrate areas where
lubrication is required.
103
Viscosity Too Low
 Insufficient oil film for proper lubrication of

components.
 Internal leakage past valve spools,
cylinder rings, pump and motor rotors.
 External leakage past cylinder seals,
pump shaft seals
ISO Viscosity Grading
ISO VG 22
ISO VG 32
ISO VG 46
ISO VG 68
ISO VG 100
The most common system for grading viscosity is the ISO

(International Standards Organization) viscosity grade. This
designation gives the fluid viscosity in centistokes (cSt) at
40ºC.
104
Viscosity Selection
Operating Temperature Viscosity Grade

95º F - 136º F ISO VG 32
35º C - 58º C
113º F - 154º F ISO VG 46
45º C - 68º C
131º F - 172º F ISO VG 68
55º C - 78º C
The fluid to be used will depend on the temperature of

the system during normal operation. Normally, system
temperature should be not exceed 65º C . Consult the
system manufacturer for exact specifications.
Coolers
Shell and Tube Plate and Frame
Most coolers are of the shell and tube type. The plate and
frame cooler has the flexibility of being able to add more
plates in a compact area for more cooling capacity.
105
Shell and Tube Cooler
Oil Out
Water In
Cold water passes through the tubes. Hot oil

passes through the shell and over the tubes.
Air Cooler
Air coolers work like the radiator on a car, blowing

cooling air over tubes through which hot oil is passed.
106
Air/ Oil Cooler – Bucket Wheel drive
Heating Element
Low Level
Switch
Heating
Elements
Heaters are usually electric resistors enclosed in

tubes. The heater is interlocked with a low level
switch to ensure it is always covered with fluid.
107
Temperature Alarms
Temp Switches
Minimum Temp – 25 Deg C
Temp Alarm- 60 Deg C
Temp TRIP- 65 Deg C
Contamination Control
108
Pressure Line Filter
Fluid cleanliness
Looking to the modern machinery requirements hydraulics

play a very active & crucial role in machine drives. As the
high-precision machinery uses advanced hydraulic
components like axial pumps & proportional/SERVO valves
maintenance of such elements is the most vital necesacity.
In hydraulics more than 80% of problems are due to
contaminated fluid & so it is important to keep system fluid
very clean & free of contaminants.
FLSMIDTH recommended oil Contamination monitoring daily
basis & Maintained the value within NAS(National Aerospace
Std 1638) 6 or ISO 4406 within 16/12/10
Life of a hydraulic component can be doubled or tripled by
lowering the NAS values.
109
Filler breather
Filler breather with filling sieve
110
Sources of contamination
Effects of contamination
111
Clearances in various hydraulic
components-01
Location of filter in hydraulic system
112
Cleaning range of ELC M/c. (General
Idea)
113
CONTAMINATION MONITORING UNIT
Pipeline flushing shall be carried out with appropriate looping

& cleanliness level shall be ensured within NAS 6/ equivalent
ISO level. Subsequently flushing shall be done integrating all
components (System level) & cleanliness level to NAS 6
(ISO 16/14/12) below shall be ensured.
CONTAMINATION MONITORING UNIT
Laser Method contamination sensor
114
Contamination level determination
method(NAS 1638)
ISO 4406 Contamination Code
2 μm 5 μm 15 μm
20/18/16
The ISO code assigns an index number to the quantity

of particles greater than 2, 5 and 15 microns in size
found in a one milliliter sample of fluid.
115
Comparison of Contamination
Classifications
Required standard of filtration
116
Some facts about contamination problem & filters
From time to time development has taken place for

better method of oil cleaning. A continuous research &
innovation is going on world-wide for Better & better
filter technology.
Contamination ingress in hydraulic system cannot be
brought to zero.
To clean the oil to a certain class is not difficult but what
difficult is, to maintain that cleanliness level consistently
during working cycles.
As you go for fine filter you should be more careful &
prompt to keep watch on filter clogging & replacement.
We cannot keep hydraulic systems healthy without
filters & protection to hydraulic system can be given by
on-line filters only & not by other off-line cleaning
methods.
FLUSHING LAYOUT
Contamination
monitoring point
Pressure relief valve
Electrical motor
Hyd. pump
Hydraulic oil tank
Above is the layout for flushing system

The aim of flushing is to remove contamination from the inside of pipes which is
inherent or may be introduced
during assembly and welding.
117
Hose Assemblies
 BASIC HYDRAULIC CIRCUITS
118
Simple hydraulic circuit
Cylinder
Directional Valve
Pressure relief
PUMP
Regenerative circuit
To get equal speed for same pump flow

,by diverting return oil from rod end to
cap end side. Cylinder has a diff.area .
Pump On , oil flow from pump to cylinder rod end and

Cylinder will retract (A to T).
Pump on & Sol. Coil no 3 on ,pressurized oil flow
To cylinder A & B side oil will join again A side for equal
Speed.
119
Load holding circuit
1) Pilot Check valve

2) Counter balance valve
3) Flow control valve
Load holding circuit using Check-Q-

Meter/over-centre valves
120
Stacker
Hydraulic Cylinder
( Cylinder location may differ in original ckt)
Stacker Circuit
Brake
Valve with
Safety
relief
DC
valve
Hydraulic
PRV Cylinder
Filter
Brake
Pump Valve with
Heater Safety
relief
Oil tank
Oil Level sensor
121
JIB STACKER
Hydraulic Luffing Stacker (JIB)
 Oil Tank
 Pump
 Temp Sensor
 Oil level Indicators
 Pressure Relief Valve
 Heater
 Breather
 filter
122
HPU
Pressure Relief Valve - 170 bar
DC valve
Pump
PUMP
Breather PRV
DC valve
Oil Level Indicators

PRV Delivery Line
Hydraulic Cylinder & Connections
123
Hydraulic Cylinder
Cap End
Load Holding or Brake Valve
124
Boom Down
PUMP ON SOL a ON Oil to Cylinder Bottom B port
P to B
a b
Boom UP
PUMP ON SOL b ON Oil to Cylinder Rod End(Top) port
P to A
a b
125
Normal Operation
Operation
126
SF-COOLER CIRCUIT Hydraulic. cylinder
Closed loop Pump

Accumulator
Pr Line Filter
Booster E-MOTOR
pump
Oil tank
Flushing Valve
CONTENTS
 Introduction
 Oil tank with Accessories‘
 Conditioning Pump
 Axial Piston Pump, A4VG with Internal booster
unit
 Proportional Valve & Pump Card VT-VSPD
 Accumulator Safety Block
 Hydraulic Cylinders
 Hydraulic Circuit in operation.
127
Reservoir
Pump
Lubrication/cooling/filter
Return oil
Hand Pump Heating Valve(25 bar)
Return oil filter
Pump delivary
45 bar
L1- L1
Warning L2
L2-Stop Temp
1000 ltrs
sensor
Suction
Limit switch
Strainer
Oil Cooler
Water
Gear Pump(32 lpm)
valve
Oil drum
Oil filling and conditioning

Water valve
for oil cooler
Water
strainer for
oil cooler
Conditioning
pump
3-way Hose for

ball valve fill/empty
function
Connection for
Connectio
emptying tank
n for filing
tank
128
Conditioning
circuit
pressere
Breather Healing Hand

filter Valve pump
Return line
double filter
Pump
lubrication
Hose for filter
hand pump
Return line filter

Clogging
Change indicator
over
valve
Return line
filters
129
Filling/drain and conditioning pump
Hose from
oil drum
connects
here
Pump
delivary
Suction
hose from
tank
Pipe from
Standby pump
Main
pump
2
Suction
Header line
Standby
pump
130
Stand
pump By
line
booster
flushing filter
filter
Main
pump
Line
Closed loop Piston Pump A4VG series(Rexroth)
Booster pump
Prop DCV
R Port
Port B
Pump
shaft High Pr Relief
valves(A & B) 280
bar
Booster Relief
valve(35 Bar)
Drain T2
Mechanical centering adjustment
131
B Pressere
Pump Proportional line Relief set
Lubrication valve(EP2)
at
Pressere 280bar
Cut off
250bar
Boost/
Pilot oil
IN
Suction
ball
valve
A
Boost/ Line
Case
Pilot oil
Suction Return High Boost
OUT
Pressere pressere
relief relief
valve valve
280bar 35bar
Close loop PUMP A4VG – Side view Hydraulic

Main Pump-The movement of a drive is controlled by a prop valve , which is
able to deliver oil flow in two directions.
Booster Oil Pump- the booster pump ensures that a sufficient oil volume is
constantly maintained on the suction side of the main pump.
132
SFC -CYLINDER
Double
acting,
double rod
cylinder
133
Cylinders and pump set-up for one grate
section.
(Schematic view 1x3)
Variable disp. closed loop pump with

Motor circuit
Closed loop pump

A4VG
134
Variable disp. Closed loop with High
Pressure relief valves
High Pressure Relief valve set at 280 Bar
Set at 280
Bar
A4VG- with booster circuit
 Booster Pressure Relief set at 35 Bar
Booster
pump
Set at 35 bar
135
A4VG with Prop DCV & Flushing Valve
Prop Flushing
DCV valve
Orifice
Closed loop circuit
Pump Return oil Booster pressere switch

lubrication
Booster pressure gauge
Accumulator
safety block
Accumulator
drain (to
Proportional reservoir)
valve Boost pump
delivary
Port B
Port A
Suction
136
N2 20 Bar Switch-25
charged bar
Pressure relief
Pressure cut
off (compen-
sation)
35bar Boost Pump

Main Pump
250 bar
280 bar
Pump Control
137
ACCUMULATOR SAFETY BLOCK
Drain Valve(24V)
Ball Valve
Manual Drain
Other Instruments-
>Proximity switch
>Pressure transmitter
>Flow switch
>Pressure switch
>Level Switch
138
Pressure Switch
-The function of pressure switch is to check that a sufficient pressure is

maintained in the booster system. The main pump stops incase of a pressure
drop to level below 25bar.
Pressure Transmitter
To Indicate the actual Pressure available in line in the form of analog signal(4-
20mA).
Used in hydraulic circuit- For all drive -A & B line
Pressure transmitter
139
Position Transmitter
To get the actual position of cylinder, which is connected near to
cylinder in cooler inside. LVDT Range has to define as per
specification of cylinder stroke. Normally the range is 0-200 mm.
Flushing(bleed-Off) Valve
Flow Switch
Flushing Valve
140
Drain FlowSwitch
Stand byPort-A
Stand byPort-B
Accumulator
Drain valve
Main
Pum
p Booster oil
M Pump PROP. Valve A4VG
Drain
Supply
Bearings
Return
Cooling Valve
START
Oil Conditioning
Heating
Valve
START
Drive
Filter
Oil tank
M
LVDT
PRIMARY SECONDRY
LVDT
PRIMARY SECONDRY
LVDT
PRIMARY SECONDRY
150mm
200mm
49.5 Kw RANDOM MODE

85.5A
MODES OF OPERATION
RANDOM MODE
141
LVDT
PRIMARY SECONDRY
LVDT
PRIMARY SECONDRY
LVDT
PRIMARY SECONDRY
150mm
200mm
49.5Kw
85,5 A
SYNCRO MODE
LVDT
PRIMARY SECONDRY
LVDT
PRIMARY SECONDRY
LVDT
PRIMARY
SECONDRY
150mm
200mm
49.5 Kw
85.5 A SHUTTLE MODE
142
CB-COOLER CIRCUIT
Hydraulic. cylinder
Closed loop Pump

Accumulator
A
Pr Line Filter
Booster E-MOTOR
pump
B
Oil tank
Flushing Valve
A Pressure in Port A-Forward , Pressure in Port B-Reverse
Hydraulic Drive System
 Hydraulic Power Unit
143
General introduction and description
 The FLSmidth Cross-Bar Cooler hydraulics is based on a closed

loop system. In basic it is similar to the system known from the
SF cooler.
 The main function of the hydraulic system is to move a

number of lanes in the cooler forward and backwards in a 3
step cycle.
 Step one: All lanes moving forward together
Step two: Every second lanes moving back
Step three: The remaining half of lanes moving back
 The Hydraulics drive system can be divided into 3 sections.
CB COOLER PUMP
One pump = one lane
144
Hydraulic Drive System
 Hydraulic Power Unit
 Pipe Package
 Cylinders
Oil tank with accessories

RetrnRrelinfiler
Return filters
Breather
Pressure relief valves
Oil Level
Gauge
Man hole for Oil Cooler

Cleaning(2)
Filling/Boosting Pump
Conditioning Pump
145
Reservoir Level sensor Air filter
 The reservoir is applied with a

Level sight glass
divider wall. One side for dirty
and warm oil, comming from
cylinders and pump drain.
 The other side is for clean and

cool oil. This is here the main
pumps have the suction line.
 On top of reservoir the

ultrasonic level transmitter will
indicate the actual oil level, 0-
100%, at the Local Control
Panel through the PLC Ultrasonic level
sensor
 Analogue electronic
measurement for oil
temperature installed inside of
reservoir
Reservoir
Oil level
Return line
Sensor
Duplex
filter
Fiiling/Emp
tying/heati
OIL TANK ng pump
Filling
Pump filter
Conditioning
pump Heating/ext
Booster
Valve
146
Reservoir
Oil level Manual

Sensor door
OIL TANK
oil emtying
hose oil Filling
hose
Tank
Drain
Reservoir
Return line
Air Breather
Duplex
filter
Water sol
valve
Heat
Exchanger(
2 Nos)
Water
inlet Water outlet
147
OIL level Indictors /Sensors
Oil Indicators
Sensor
High High Trip- 95%

High Alarm-92%
Low-Alarm- 70%
Low Low-Trip- 50%
Filling & Conditioning Pump
Oil emtying Pressure

ball valve Gauge
Filling
Pump
Conditioning
Pump
148
Multipurpose filling pump
The filling pump has different

purposes.
Heating valve with filter
1. Filling the oil reservoir from oil
barrels through first a pressure
filter and secondly through the
conditioning filter.
2. Filling pumps and pipe system.
3. Preheating the oil through

heating valve.
Filling pump unit
Conditioning circuit.
 Purpose of conditioning circuit

is to cool and clean the oil
continuously. It takes the oil Water valve Conditioning pump unit
from the dirty side and returns

it to the clean side for main
pump suction.
 The oil/water cooler is a plate

type with water strainer and
water valve at the inlet. The
valve will control the water flow
depending on the oil
temperature. Secondary water cooler
 Tank top mounted conditioning Visual

filter at 6 micron with clogging indicator
indicator installed.
Pressure
transmitter
149
Screw Pump- Oil Conditioning
Screw pumps are low pressure pumps, often used for lubricating oil
delivery. They are not used in high pressure hydraulic applications.
Oil Filling & Boosting Pump
Suction
hose from
tank,Handl
e position
Suction as shown
Handle
hose from by arrow
Down-Oil
tank filing from
DRUM
150
Heating & Filing Solenoid Valve
For heating Energize Solenoid B

For Priming/Flushing Main Pump ON
Sol A
Return Filter(Filing/conditioning)
Accumulat
Manual or drain
Clogging line
indicator
Clogging
Signal
2bar- 75%
clogged.
3 bar 100%
clogged
151
Return line filter(Case drain/flushing)
Clogging
Signal
2bar- Change over
75% valve ( 180
clogged. deg
2.5 bar rotation)
100%
clogged
Right Side
Filter
Left Side
Filter
Manual
Clogging
indicator Presently Oil is Return line
Passing to Left side filters
Filter ,as per Handle
shown,
Main motor pump unit
 The unit consist of electrical

motor, bell housing, coupling
Hole for coupling inspection
and pump.
 Motor and pump is connected

with a coupling consisting of a
motor hub, a pump hub and a Hole for oil drain
spider in between.
 The unit is mounted on

vibration dampers.
152
Principle -Axial variable piston pump
A4VG Closed
circuit
Main pump
 Pump is a variable
displacement pump equipped
with internal auxiliary pump for
boost and pilot pressure.
 The proportional valve on top

of the pump, controls the
output of the pump via the PLC.
 Out put/flow rate and direction

through either A or B pressure
ports, are determined by the
position of the swash plate
Proportional valve
153
Closed loop Piston Pump A4VG
Booster pump
Port B
Pump
priming
Prop DCV
Pressure
Sensor
Swash
angle
sensor
A4VG-PORT OVERVIEW
154
Booster B
High Lines line
Pressere
Relief
385bar
Pressere
Cut-Off
set @ 250
bar
A Line
Suction
Case FerroMag
drain netic
sensor
Accumulator
Bladder accumulator
 The bladder accumulator will

backup boost and pilot
pressure.
Accumulator safety
block
 Nitrogen gas inside bladder.
 Safety block with boost filter,

boost pressure manometer,
electrical pressure relieve
valve, manual pressure relieve Manual
Accumulator
isolating handle
valve and isolating valve for relieve valve
service Electrical
relieve valve
Boost filter
155
BOOSTER FILTER
Pressure
Sensors(inlet/outlet)
Alarm-3.75 bar
TRIP-5 bar(24 hrs
Delay) FILTER
HPU with standby pump
 HPU supplied with standby

pump
 Standby pump can replace any

other main pump so operation
can be continued. Pump size Standby handles at
and type is equal to a main coolers with end-HRB
pump.
 Standby pump can also be use

for flushing purpose
 Handle(s) down = Normal

service
 Handel(s) up = Standby
operation
156
Cylinders
 Inlet and outlet cylinders are

installed in opposite directions
for having the same oil
volumen in both transport and Minimess connection
return stroke.
 Applied with protective hose

sleeves.
 Equipped with maintenance

free bearings and minimess
connections for bleeding.
Protective hose
sleeves
CYLINDER SROKE
20 mm
To
320mm
Stroke 340 mm
WORKING STROKE: 240 -280mm(Max 300mm) with 2.5-9 SPM
157
Interconnecting Pipe lines
Flushing Valve
Check Valve direction

& Oil flow
Flushing
Flow Switch
Valve
158
Pump Control Card
WEST REXROTH
Drive in operation
159
Pump Station
Cylinder Lines
Accumulator Station
Delivery Ball Valve
Closed Loop Drive Pump
CB Cooler
Cylinder
Flushing Valve
DR1 DR2 DR3 DR4
160
LVDT
PRIMARY SECONDRY
LVDT
PRIMARY SECONDRY
LVDT
PRIMARY
SECONDRY
240-300mm
340mm
49.5 Kw
85.5 A ONLY SHUTTLE MODE
SHUTTLE MODE
Online Oil Filling/Filter change

For Conditioning Filter Change – Enable Online Filter Change
Both Pump M01 & M02 will stop for filter change
Online Filling:
Enable oil Filling in
Face plate ,Put
Drum Connected &
Turn the Handle
Down & oil will be
sucked from Drum
& after level ok,
Turn down handle
to normal Position
& Disable Online oil
filling
161
Cooler Drive(Other Circuit)
Hydraulic
Cylinder with
Accumulator
& Proportional
Valve
Unloading Safety
Relief Valve
Set@220 Bar
Oil
Conditioning
Circuit
Oil Pump Pump

Tank ikn
Cooler Drive(IKN-PU)
PT Unloading
P T Safety Relief
Valve
Set@220 Bar
NRV
Pump Pump
Oil
Tank
162
163
Clinker Cooler Drive Schematic
CLICKER COOLER GRATE

PRE STROKE
RETURN
STROKE
Cylinder
Variable Displacement
Closed loop Piston Pump
Conveying Track-1
GRATE-1
GRATE-2
Scavenging Valve
Hydraulic Cylinders
ELE.MOTOR
PISTON PUMP(181LPM) PISTON PUMP(105LPM)
164
Hydraulic thrust device
1. Hydraulic pr. always keeps the thrust roller in contact with tyre
face
2. Taper roller ensures the tangential velocity through out the
contact length is uniform
3. Hence pure rolling action occurs and eliminates slip
4. Design of hydraulic circuit keeps the kiln in axial balance
condition
5. Spherical roller bearing at top and thrust roller bearing at bottom
take up radial and axial load
Hydraulic Thrust Device
Pump ON- Kiln UP
DC Valve ON –Kiln Down Kiln position

Sensor
Accumulator
Pr Gauge
PT Relief Valve
Check valve with Orifice
DC Valve
Breather Return Filter
NRV
Oil Level Sensor
TANK
PUMP
Suction Ball Valve
165
Kiln HTD- PU
Suction Valve
Accumulator
Drain
Motor
Piston Pump
Pressure Compensator set@75 bar
Kiln-HTD
Flow Control
Valve
Flow Control
Valve
-CLOSED
-OPEN
166
Kiln-HTD Limits & Alarms
Operating: Alarm- +- 10MM

Position Sensor & Pressure less
than 10 bar
+5 mm
0
TRIP; +- 15MM
- 5mm
Flow Control
Valve
Flow Control
Valve
-CLOSED
-OPEN
KHD- Kiln Thrust

DC Valve – For raising Cylinders
FCV
Relief Valve
Filter Poppet DC valve

for lowering
Pump Pump
167
Kiln Thrust (China Make)
Clinker Roll Breaker

Transport Crusher Crusher
Roll Roll 1 Roll 2
Standby
Pump
168
Reclaimer Chain Tensioning Device
Hydraulic Cylinder
PT
Manual DC valve-Kept in Tensioning
Sequence Valve/Safety Relief
Piston Pump –Set@70 bar

Filter
TANK
Reclaimer Chain Tensioning Device
Hand operated valve is kept one side

by pressurizing the cylinder cap end,
cylinders are always in extended.
The pump is continuously running whenever
the conveyor is running.
Pump will de-stroke when it reaches
set pressure( 70) ,a pressure switch stop the
conveyor when pressure drops less than 30 bar.
169
Triple Gate Hydraulic System
Roller Mill Swing-out Cylinder
170

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BASIC & VRM HYDRAULICS TRAINING

Venue : Fern Residency, Udaipur

 Introduction to oil  Atox mill Hydraulics

© 2013 FLSmidth. All Rights Reserved

Transmission & control

We use the ability of fluids to transmit power or to perform a task

© 2013 FLSmidth. All Rights Reserved

Transfer of Energy in Hydraulic circuit

© 2013 FLSmidth. All Rights Reserved

Hydraulic Cylinder With Accumulators

PT Transmitter for GR Pr & N2 Pr

© 2013 FLSmidth. All Rights Reserved

OK Mill Ver3 Hydraulic Circuit

Vane Pump Conditioning Pump

© 2013 FLSmidth. All Rights Reserved

Closed loop Pump

A Pressure in Port A-Forward , Pressure in Port B-Reverse

© 2013 FLSmidth. All Rights Reserved

HRP- Hydraulic Circuit

© 2013 FLSmidth. All Rights Reserved

Supply Lines to 3 Rollers Breather /Overflow lines Return lines

© 2013 FLSmidth. All Rights Reserved

Loesche Mill Hydraulic Circuit

Hydraulic Cylinder with

© 2013 FLSmidth. All Rights Reserved

© 2013 FLSmidth. All Rights Reserved

Raw Mill (Kawasaki)

DC Valve Pilot Op Check

© 2013 FLSmidth. All Rights Reserved

© 2013 FLSmidth. All Rights Reserved

© 2013 FLSmidth. All Rights Reserved

© 2013 FLSmidth. All Rights Reserved

© 2013 FLSmidth. All Rights Reserved

© 2013 FLSmidth. All Rights Reserved

© 2013 FLSmidth. All Rights Reserved

© 2013 FLSmidth. All Rights Reserved

Simple hydraulic circuit (Symbolic

© 2013 FLSmidth. All Rights Reserved

© 2013 FLSmidth. All Rights Reserved

Hydraulic Line Pilot Line or Drain Flexible Line

Connecting Lines Passing Lines

Tank Line to Tank Equipment Enclosure

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Fixed Displacement Pump

Pump with Motor

Variable Displacement Pump

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Pressure Compensated Pumps

Pressure Compensated Pump

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Linear Actuators Rotary Actuators

Single Acting Hydraulic

Double Acting Bi-Directional

Double Rod Variable

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Check Valve, Spring Biased

Shuttle Check Valve

Pilot Operated Check

Pilot Operated Check

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Flow Restriction, Fixed

Flow Control Valve

Flow Control Valve, Temperature