UNIT 1 - INTRODUCTION TO HYDRAULICS & PNEUMATICS

Marks – 06

Fluid Power

Fluid Power is the branch of engg. science, which deals with the power transmission
employing pressurized liquid or gas to transmit energy from an energy generating source to
an energy use area.
Fluid power is subcategorized as –
1. Hydraulics
2. Pneumatics

Advantages of Fluid Power

1. Simpler design - In most cases, a few pre-engineered components will replace
complicated mechanical linkages.
2. Flexibility - Hydraulic components can be located with considerable flexibility. Pipes
and hoses instead of mechanical elements virtually eliminate location problems.
3. Smoothness - Hydraulic systems are smooth and quiet in operation. Vibration is kept
to a minimum.
4. Control - Control of a wide range of speed and forces is easily possible.
5. Cost - High efficiency with minimum friction loss keeps the cost of a power
transmission at a minimum.

Limitations of Fluid Power

1. The material of storage tank, piping, cylinder and piston can be corroded with the
hydraulic fluid. Therefore one must be careful while selecting materials and hydraulic
fluid.
2. The structural weight and size of the system is more which makes it unsuitable for
the smaller instruments.
3. The small impurities in the hydraulic fluid can permanently damage the complete
system, therefore one should be careful and suitable filter must be installed.
4. The leakage of hydraulic fluid is also a critical issue and suitable prevention method
and seals must be adopted.
5. The hydraulic fluids, if not disposed properly, can be harmful to the environment.

Applications -
 Industrial applications -
 Tilting, pushing and loading etc.
 Work holding devices
 Hydraulic presses
 Transport applications

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  Hydraulics brakes, air brakes, power steering
 Construction equipments
 Earthmoving machinery
 Hydraulic & pneumatic breakers
 Concrete machinery

Properties of Hydraulic Fluid -

 Viscosity:
 Viscosity is the resistance to flow and it is considered as an important
property of fluids.
 For a hydraulic system, the viscosity is inversely dependent on the
temperature. As the temperature increases, the viscosity will decrease and
internal leakages occur.
 When the temperature decreases, the viscosity will increase and it will resist
the flow of fluids.
 Using hydraulic fluids with suitable viscosity will reduce flow losses and
provide precise control over the system.
 Absolute Viscosity:
 Absolute Viscosity or Dynamic viscosity is defined as the force (F) required to
move a flat surface of unit area (A) at unit velosity (v) when it is separated by
a unit thickness (d).
 SI unit of Absolute Viscosity is N/m2.sec or Pa-s.
 Kinematic Viscosity:
 Kinematic Viscosity is the function of Absolute Viscosity. It is defined as the
ratio of Absolute Viscosity to mass density of fluid.
 SI unit of Kinematic Viscosity is m2/sec.
 Viscosity Index:
 Ideally the viscosity of oil should remain same at all operating temperatures.
But it is not true in practical cases.
 The viscosity of oil decreases with increase in temperature. This rate of
change of viscosity with temperature is defined as Viscosity Index.
 In order to have satisfactory functioning of hydraulic systems it is that oil
should have higher VI.
 Lubrication:
 Lubrication reduces the friction and protects the system components against
wear.
 Lubrication property of the hydraulic fluid means creating a strong film with
fluid that can’t be wiped out with the moving surface.
 Chemical Stability:
 The chemical stability or resistance to oxidation is defined as the fluids ability
to resist oxidation and chemical changes that appear in the fluid due to
influence of higher temperature and catalytic effects of metals for long
periods.

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  Minimum compressibility:
 Most of the hydraulic systems work under Pascal’s principle. So, the
incompressible property of the fluid is essential for efficient operation. This
property helps in generating a higher force by applying a small force on a
larger area.
 Demulsibility:
 Demulsibility is the property of the fluid to release water.
 The presence of water in the system will create many contamination related
issues and will result in corrosion and damage.
 Fire Resistance:
 We have both petroleum based and fire resistant hydraulic fluids.
 A high risk of fire is present in fluids that are used with coal mines and hot
metal processing equipment due to high temperature.
 So, in such applications always prefer fire-resistant hydraulic fluids.
 Flashpoint and fire point are the common characteristics to determine the fire
resistance of fluid.
 Flash point is the lowest temperature at which a liquid can form an
ignitable mixture in air near the surface of the liquid. The lower the flash point,
the easier it is to ignite the material.
 Fire point is the temperature at which the flame becomes self-sustained so as
to continue burning the liquid (at the flash point, the flame does not need to be
sustained). The fire point is usually a few degrees above the flash point.
 Foam Resistance:
 Foam is a collection of small bubbles of air that accumulate on or near the
surface of the fluid.
 Foaming occurs as a result of fluid contamination, poor system design,
cavitation, etc. This can be a reason for the overflow of fluid from the
reservoir.
 Material compatibility:
 To ensure long life and maximum performance, one needs to check the
compatibility of fluid with the material (metals, rubber and elastomer
components) the system use.
 Heat Removal:
 Continuous flow of fluids through the system will increase the temperature of
both fluid and system components.
 This will create malfunctioning of the system components.
 So, the system requires good heat dissipation property.

Requirement of Good Fluid –

 It should have moderate viscosity, so that it could flow easily as we as seal the
clearances between mating parts.
 It should have high viscosity index, so that it can perform same over given range of
temperature.
 It should have high demulsibility.

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  It should have good lubricity.
 It should remain chemically stable over expected period of service.
 It should have good air separating ability.
 It should be non corrosive to metals in hydraulic system.
 It should have high good filterability.
 It should have flash point well above the maximum operating temperature in normal
operation.

Pascal’s principle

Pascal’s law states that the pressure generated by exerting a force on a confined mass of
liquid at rest acts undiminished in equal magnitude and in all directions normal to the inside
wall of the fluid container.

From the figure, if a force F is applied on the confined liquid in the jar, a pressure p is
generated and this pressure p will act on the inside wall of the container undiminished i.e. in
equal magnitude and at right angles to the point where pressure acts on the surface.

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Pressure is equal to the force divided by the area on which it acts.

According to Pascal’s principle, in a hydraulic system a pressure exerted on

a piston produces an equal increase in pressure on another piston in the system. If the
second piston has an area 10 times that of the first, the force on the second piston is 10
times greater, though the pressure is the same as that on the first piston. This effect is
exemplified / Illustrated by the hydraulic press, based on Pascal’s principle, which is used in
such applications as hydraulic brakes.

Factors affecting selection of Hydraulic Fluids

1. Operating Pressure
This has a predominant effect on selection of hydraulic fluids, since different
oils behave differently at different pressures. Viscosity of oil is also a function
of pressure. Hence for a given oil to be suitable to an operating pressure, the
oil should exhibit viscosity changes with pressure within tolerable limits.
Generally synthetic oils are used at higher pressures.
2. Operating temperature
This is another important point to be considered in selection of oil. Water
based hydraulic fluids are not suitable for high temperature applications. Oil
used in hydraulic system operating at higher temperature should have higher
viscosity.
3. Operating environment
While selecting hydraulic fluid for a hydraulic system the operating
environment of the hydraulic system should be considered. In hostile and fire
hazardous environment petroleum based oils are never used, in such
environment water based oils are used as they exhibit excellent fore proof
characteristics.
4. Water retention
Large amounts of water in hydraulic oil can be removed by regularly draining
the reservoir. Small amounts of water can become entrained, especially if the
reservoir is small. Demulsifiers are often added to the fluid to speed up the
separation of water. Filters can remove any remaining water from the
hydraulic oil. Water should leave the oil without taking fluid or additives with it.
5. Seal compatibility
In most systems, seals are selected so the hydraulic fluid will not change their
size or shape, ensuring tight fits. The fluid selected should be checked to
ensure that the fluid and seal materials are compatible.
6. The expected service life of the hydraulic fluid also needs to be considered.
7. The contamination possibilities should be considered while selecting the fluid as
contamination can cause severe problems in the system.
8. Cost considerations
9. Compatibility of the fluid with the parts being used in the system plays an important
role in the selection.

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Hazards in Hydraulic System -

Hydraulic equipments and systems are designed to accomplish work using confined liquid
pressure to produce a greater mechanical force. The operators/ maintenance crews are
subjected to hazards from high pressure liquids and large mechanical forces. Hydraulic
systems store fluid under high pressure.
The workmen are exposed to following hazards:
1. burns from hot, high-pressure fluid
2. Injection of fluid into the skin
3. Fire Hazards
4. Bruises, cuts or abrasions from flailing hydraulic lines
5. Injury of people due to unexpected movement of equipment
6. During maintenance of equipment and their parts.
7. Injury due to sudden release of residual pressurized oil.
8. Slippage due to oily floor area.
9. Electric shock from electrical motors/ A.C. Solenoids

Safety Precautions in Hydraulic System –

Before starting any hydraulic system care should be taken to avoid accidents. The general
safety precautions to be followed are as follows -
1. Depressurize the system before start of work. Shut down/ Local Isolation may be
taken, if required.
2. Never begin work on a hydraulic system until fully trained.
3. Never begin work on a hydraulic system without using a risk assessment.
4. Carefully review the manuals of equipments before beginning work. Ask questions
about anything you do not fully understand.
5. Read the Material Safety Data Sheet (MSDS) for chemicals used.
6. Use all required safety Equipments.
7. Never try to repair a part without having full knowledge about it.
8. Each hydraulic system must have a documented procedure of de-energizing and
load locking. This should be known to all maintenance personnel.
9. Document and practice de-pressurizing procedure in each of the circuit.
10. While testing the system after repair never stand close to the unit. Any component,
pipe, hose, fitting may fail.
11. Before start of work, drain the pressure line through minimesh point upto the
actuator.
12. Drain the accumulator, if any, from drain valve and check oil pressure from minimess
coupling provided in safety block or main pressure line after accumulator. If pressure
gauge is showing zero, then also bleed the accumulator with minimess hose for
confirmation.
13. During the tightening of pressurized lines hammering should not be done.
14. Tightening of Joints should be done in depressurized condition.

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 15. In any of the hydraulic maintenance jobs, all other agencies working in that area
should be well communicated about the hydraulic work and its effects.

Safety Precautions in Pneumatic System –

1. Do not exceed the maximum permissible pressure of 600 kPa (6 bar).

2. Do not activate compressed air until all of the tubing connections have been
completed and secured.
3. Do not disconnect tubing while under pressure.
4. There is a danger of injury when switching compressed air on as the cylinders may
advance and retract automatically.
5. There can be danger of accident due to tubing slipping off!
6. Wear safety glasses.
7. Compressed air can cause severe damage to people. Never spray anyone with
compressed air and never let compressed air enter a human cavity, like the nose
or ear.
8. When compressed air is released through the exhaust, the air will contain oil
droplets and other particulates that can damage the eyes and respiratory
system.
9. Compressed air in pipes can cause explosions even if the reservoir is relatively
low.
10. Prior to switching systems on, the whole circuit should be inspected for possible
loose parts, damaged pipes, or any abnormal pressure.
11. If leaks are detected while using a system, work should immediately stop.
12. In the event that tubing slips off, switch compressed air supply off immediately.

Hazards in Pneumatic System –

By blowing the air at another person, or even themselves, it can quickly result in
problems. The following are some major hazards in pneumatic system -
1. Internal Ruptures –Since the air comes out very quickly, it can be forced down
into the lungs, stomach or even intestines. When this occurs, they can rupture
and cause very serious injury or even death.
2. Broken Skin – When blowing compressed air on the skin it can actually break
through it, and enter the bloodstream. In addition to the serious skin damage, this
air in the blood stream can cause death as it makes its way through to the heart
and brain.
3. Blindness – The pressure from the air can cause very serious injury when it
comes in contact with your eyes. The damage can happen in an instant, and
result in permanent blindness.
4. Blowing Objects – If someone blows the compressed air at different objects, such
as tools, they can be accelerated to very fast speeds. This can cause a major
projectile risk within the facility.

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 5. Damaging the Facility – Compressed air not only puts people at risk when it is
not treated properly, but also the facility. The high pressure air can, for example,
blow off paint from a machine. It could also potentially blow floor marking tape,
labels or any number of other things from where they need to be.

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