Industrial Fluid Power

Unit 1
Introduction to Fluid power and Source of
Fluid Power
• Part A:
– Fluid power systems: Components, advantages,
applications. Hydraulic fluids, Properties of fluids,
selection of fluids. sources of contamination and
contamination control.
– Pumps: Types, classification, working and constructional
details , characteristics . Power units and accessories, Types
of power units, reservoir assembly.
 Introduction

• Methods for transmitting power from one point to another

– Mechanical transmission is through shafts, gears, chains, belts, etc.
– Electrical transmission is through wires, transformers, etc.
– Fluid power is through liquids or gas in a confined space.

• What is fluid power?

– Fluid power is the technology that deals with the generation, control
and transmission of forces and movement of mechanical element or
system with the use of pressurized fluids in a confined system.
 Introduction

• Fluid power system includes a hydraulic system (hydra

meaning water in Greek) and a pneumatic system (pneuma
meaning air in Greek).
• Hydraulic system employs pressurized liquid petroleum oils
and synthetic oils whereas pneumatic system employs
compressed air that is released to the atmosphere after
performing the work.
 Introduction
• Some drawbacks of water as a hydraulic fluid:
– Pure water contains various chemicals (some deliberately included) and
also foreign matter, and unless special precautions are taken when it is
used, it is nearly impossible to maintain valves and working surfaces in
satisfactory condition.

– In addition to power transmission, benefits of lubrication not afforded

by water as well as increased life and efficiency of packings and valves.
– Water freezes at low temperature and hence can not be used for low
temperature applications.
 Introduction

• Types of fluid systems:

– Fluid transport system

• Transport of water from reservoir using pipe lines
• Transport of oil in pipe between different countries.

– Fluid power system

• Oil used in hydraulic system to acquire desire movement.
• Compressed air in pneumatics to obtain desired mechanical output.
 Introduction
• Advantages of fluid power:

1. Fluid power systems are simple, easy to operate and can be controlled accurately:
• Fluid power gives flexibility to equipment without requiring a complex mechanism.

• Using fluid power, we can start, stop, accelerate, decelerate, reverse or position large
forces/components with great accuracy using simple levers and push buttons.

• For example, in Earth-moving equipment, bucket carrying load can be raised or

lowered by an operator using a lever. The landing gear of an aircraft can be retrieved
to home position by the push button.

2. Multiplication and variation of forces:

• Linear or rotary force can be multiplied by a fraction of a kilogram to several hundreds of
tons.
 Introduction
• Advantages of fluid power:
3. Multifunction control:

• A single hydraulic pump or air compressor can provide power and control for
numerous machines using valve manifolds and distribution systems.
4. Low-speed torque:
• Unlike electric motors, air or hydraulic motors can produce a large amount of torque
while operating at low speeds and deliver constant torque or force regardless of speed
changes.
5. Economical:
• Reduction in required manpower
• Lower cost of the components in the systems.
 Introduction
• Advantages of fluid power:

6. Constant force or torque:

. Fluid power systems can deliver constant torque or force regardless of speed changes.

7. Low weight to power ratio:

• The hydraulic system has a low weight to power ratio compared to electromechanical
systems.
• Fluid power systems are compact.
8. Fluid power systems can be used where safety is of vital importance:

. Safety is of vital importance in air and space travel and is taken care of by fluid power.
 Introduction
• Disadvantages of fluid power:
– Hydraulic systems
• Hydraulic oils are messy
• Leakage is impossible to eliminate
• Bursting of hydraulic lines

• Fire : especially if oil leakage occur in high temperature zone.

– Pneumatic systems

• High pressure air tank and accumulators can explode if the pressure
exceed beyond designed limit.
 Introduction
• Applications of Fluid Power:
– Stationary unit
• Machine tools and transfer lines.
• Lifting and conveying devices.
• Metal-forming presses.
• Plastic machinery such as injection-molding machines.
• Rolling machines.
• Lifts.
• Food processing machinery.
• Automatic handling equipment and robots.

– Mobile unit
• Automobiles, tractors, aeroplanes, missile, boats, etc.
• Construction machinery.
• Tippers, excavators and elevating platforms.
• Lifting and conveying devices.
• Agricultural machinery.
 Introduction
• Basic components of hydraulic system
 Introduction
• Basic components of hydraulic system:
1. The hydraulic actuator is a device used to convert the fluid power into mechanical
power to do useful work.

2. The hydraulic pump is used to force the fluid from the reservoir to rest of the hydraulic
circuit by converting mechanical energy into hydraulic energy.
3. Valves are used to control the direction, pressure and flow rate of a fluid flowing
through the circuit.
4. External power supply (motor) is required to drive the pump.

5. Reservoir is used to hold the hydraulic liquid, usually hydraulic oil.

6. Piping system carries the hydraulic oil from one place to another.

7. Filters are used to remove any foreign particles so as keep the fluid system clean and
efficient, as well as avoid damage to the actuator and valves.

8. Pressure regulator regulates (i.e., maintains) the required level of pressure in the
hydraulic fluid.
 Introduction
• Basic components of hydraulic system:
 Introduction
• Basic components of pneumatic system:
 Introduction
• Basic components of pneumatic system:
1. The pneumatic actuator converts the fluid power into mechanical
power to perform useful work.
2. The compressor is used to compress the fresh air drawn from the
atmosphere.
3. The storage reservoir is used to store a given volume of compressed
air.
4. The valves are used to control the direction, flow rate and pressure of
compressed air.
5. External power supply (motor) is used to drive the compressor.
6. The piping system carries the pressurized air from one location to
another.
 Introduction
• Comparison between hydraulic and pneumatic systems:
 Introduction
• Pascal’s Law:
– Pascal’s law states that the pressure exerted on a confined fluid is
transmitted undiminished in all directions and acts with equal force on
equal areas and at right angles to the containing surfaces.
– Pressure in a fluid acts equally in all directions and this pressure acts at
right angles to the containing surfaces.
 Introduction
• Pascal’s Law:
– Multiplication of force
• The most useful feature of fluid power is the ease with which it is able to multiply
force. This is accomplished by using an output piston that is larger than the input
piston.
 Hydraulic Fluids
• Primary functions:
– Transmit power
– Lubricate moving parts
– Seal clearances between mating parts
– Dissipate heat

Generally following fluids are used:

• Hydraulic systems : Water, petroleum oils, synthetic oils.
• Pneumatic systems: Air
 Hydraulic Fluids
• Desirable properties (Hydraulic system):
1. Good lubricity
2. Ideal viscosity
3. Chemical stability
4. Compatibility with system materials
5. High degree of incompressibility
6. Fire resistant
7. Good heat transfer capability
8. Low density
9. Foam resistant
10. Non toxic
11. Low volatility

• Desirable properties (Pneumatic System):

1. Fire resistant
2. Should not be messy
3. Can be exhausted back into the atmosphere.
 Hydraulic fluid
• Density:
– The density of a fluid is its mass per unit volume:

• Specific Weight:
– Specific weight is defined as weight per unit volume, that is,

• Specific volume:
– Specific volume (SV) is the volume occupied by a unit mass of fluid.

• Specific gravity:
– Specific gravity (SG) of a given fluid is defined as the specific weight of the
fluid divided by the specific weight of water, that is
 Hydraulic Fluid
• Hydraulic Losses:
– Major losses (due to friction)
– Minor losses (due to pipe fittings)

• Types of flow:
– Laminar
– Transient (unpredictable)
– Turbulent
 Hydraulic Fluid
• Selection of fluids:
– Although mineral oils were readily available in the beginning of 20th century, they were
not practically used in hydraulic system until the 1920.

– In 1940s, additives were first used to improve the physical and chemical properties of
hydraulic mineral oils.
– The first additives were developed to counter rust and oxidation.

– However, mineral oils are highly flammable, and fire risk increases when operating at
high temperatures.

– This led to the development of fire-resistant fluids that are mainly water based, with
limitations on the operating conditions.

– The need for extremes of operating temperatures and pressures led to the development of
synthetic fluids.

– Personnel who operate, service, or design fluid power should have knowledge of the
individual characteristics of hydraulic fluid.
 Hydraulic Fluid
• Factors Influencing the Selection of a Fluid:
1. Operating pressure of the system.
2. Operating temperature of the system and its variation.

3. Material of the system and its compatibility with oil used.

4. Speed of operation.
5. Availability of replacement fluid.

6. Cost of transmission lines.

7. Contamination possibilities.

8. Environmental condition (fire proneness, extreme atmosphere like in mining, etc.).

9. Lubricity.

10. Safety to operator.

11. Expected service life.

 Hydraulic Fluid
• Fluid contamination:
– Hydraulic fluid contamination may be described as any foreign material
or substance whose presence in the fluid is capable of adversely
affecting system performance or reliability.
– It may be of different forms including liquids, gases, and solid matter
of various composition, sizes, and shapes.
– Solid matter is the type most often found in hydraulic systems and is
generally referred to as particulate contamination.
– Contamination is always present to some degree, even in new, unused
fluid, but must be kept below a level that will adversely affect system
operation.
 Hydraulic Fluid
• Contamination:
– Particulate contamination

– Fluid contamination

• Particulate Contamination:
– This class of contaminants includes organic, metallic solid, and
inorganic solid contaminants.

• Fluid Contamination:
– Air, water, solvent, and other foreign fluids are in the class of fluid
contaminants.
 Hydraulic Fluid
• Particulate contamination
1. Organic contamination
• Are produced by wear, oxidation, or polymerization.
• Minute particles of O-rings, seals, gaskets, and hoses are present, due to wear or chemical reactions.
• Synthetic products, such as neoprene, silicones, though resistant to chemical reaction with hydraulic
fluids, produce small wear particles.

2. Metallic solid contamination

• Metallic contaminants are almost always present in a hydraulic system and will range in size from
microscopic particles to particles readily visible to the naked eye.

• These particles are the result of wearing and scoring of bare metal parts and plating materials, such as
silver, ferrous, aluminum and chromium particles.

• Because of their continuous high-speed internal movement, hydraulic pumps usually contribute most
of the metallic particulate contamination present in hydraulic systems.

• Metal particles are also produced by other hydraulic system components, such as valves and actuators,
due to body wear and the chipping and wearing away of small pieces of metal plating materials.
 Hydraulic Fluid
• Particulate contamination
3. Inorganic solid contamination:
• This contaminant group includes dust, paint particles, dirt, and silicates.

• Glass particles may also be found as contaminants.

• Glass particles are very undesirable contaminants due to their abrasive effect on
synthetic rubber seals and the very fine surfaces of critical moving parts.
• Atmospheric dust, dirt, paint particles, and other materials are often drawn into
hydraulic systems from external sources.
 Hydraulic Fluid
• Fluid contamination
– Air, water, solvent, and other foreign fluids are in the class of fluid contaminants.

1. Air Contamination
1. Hydraulic fluids are adversely affected by dissolved, entrained, or free air.
2. Air may be introduced through improper maintenance or as a result of system design.
3. Any maintenance operation that involves breaking into the hydraulic system, such as
disconnecting or removing a line or component will invariably result in some air being
introduced into the system.

2. Water contamination
• Water is a serious contaminant of hydraulic systems.
• Hydraulic fluids are adversely affected by dissolved, emulsified, or free water. Water
contamination may result in the formation of ice, which impedes the operation of valves,
actuators, and other moving parts.
• Water can also cause the formation of oxidation products and corrosion of metallic surfaces.
 Hydraulic Fluid
• Origin of contamination
1. Particles originally contained in the system.

– These particles originate during the fabrication and storage of system components.
2. Particles introduced from outside sources.
– Particles can be introduced into hydraulic systems at points where either the liquid or certain
working parts of the system (for example, piston rods) are at least in temporary contact with the
atmosphere.

3. Particles created within the system during operation.

– Contaminants created during system operation are of two general types—mechanical (wearing of
parts) and chemical (oxidation).

4. Particles introduced by foreign liquids.

– One of the most common foreign-fluid contaminants is water, especially in hydraulic systems
that require petroleum-based liquids.
– Water, which enters even the most carefully designed system by condensation of atmospheric
moisture, normally settles to the bottom of the reservoir.
 Hydraulic Fluid
• Fluid contamination control
– Maintaining hydraulic fluid within allowable contamination limits for both water and
particulate matter is crucial to the care and protection of hydraulic equipment.

– Filters will provide adequate control of the particular contamination problem during all
normal hydraulic system operations if the filtration system is installed properly and
filter maintenance is performed properly.
 Hydraulic Fluid
• Fluid contamination control

• The following maintenance and servicing procedures should be adhered to at all times to provide proper
contamination control:

1. All tools and the work area should be kept in a clean, dirt-free condition.

2. A suitable container should always be provided to receive the hydraulic liquid that is spilled during
component removal or disassembly.

3. Before hydraulic lines or fittings are disconnected, the affected area should be cleaned with an
approved dry-cleaning solvent.

4. All hydraulic lines and fittings should be capped or plugged immediately after disconnection.

5. Before any hydraulic components are assembled, their parts should be washed with an approved
dry-cleaning solvent.
 Hydraulic Fluid
• Fluid contamination control
6. After the parts have been cleaned in dry-cleaning solvent, they should be dried thoroughly with
clean, low-lint cloths and lubricated with the recommended preservative or hydraulic liquid
before assembly.
7. All packings and gaskets should be replaced during the assembly procedures.
8. All parts should be connected with care to avoid stripping metal slivers from threaded areas.

9. All hydraulic servicing equipment should be kept clean and in good operating condition.