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Hydraulics Power Packs

 
Hydraulic Pumps

•  When a hydraulic pump operates, it performs two functions. First, its

mechanical action creates a vacuum at the pump inlet which allows
atmospheric pressure to force liquid from the reservoir into the inlet line
to the pump. Second, its mechanical action delivers this liquid to the
pump outlet and forces it into the hydraulic system.
• In this topic, the participants should be able to know:
– the different types of hydraulic pumps ( design and operation)
– the common cause of pump failures and their corrective actions
– Compute hydraulic pump power ( actual exercise)

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Definition

• WORK
• The amount of energy transferred by a force (linear or rotary).
• POWER
• Power is the rate at which work is done.
• ENERGY
• Energy is the capacity to do work.
• CAVITATION
• Cavitation is the formation of bubbles of a flowing liquid in a region where
the pressure of the liquid falls below its vapour pressure.
• NPSH
• Net positive Suction Head is the total head ( suction force) into a pump.

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Classification of Pumps

• Generally all pumps are classified as either positive displacement or non-

positive displacement. Most pumps used in hydraulic system are positive
displacement.
• A non-positive-displacement pump produces a continuous flow. However,
because it does not provide a positive internal seal against slippage, its
output varies considerably as pressure varies. Centrifugal and propeller
pumps are examples of non-positive-displacement pumps.
• If the output port of a non-positive-displacement pump were blocked off,
the pressure would rise, and output would decrease to zero. Although the
pumping element would continue moving, flow would stop because of
slippage inside the pump.
• In a positive-displacement pump, slippage is negligible compared to the
pump's volumetric output flow. If the output port were plugged, pressure
would increase instantaneously to the point that the pump's pumping
element or its case would fail (probably explode, if the drive shaft did not
break first), or the pump's prime mover would stall.

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Pump

• A pump produces liquid movement or flow: it does not generate pressure.

It produces the flow necessary for the development of pressure which is a
function of resistance to fluid flow in the system. For example, the
pressure of the fluid at the pump outlet is zero for a pump not connected
to a system (load). Further, for a pump delivering into a system, the
pressure will rise only to the level necessary to overcome the resistance of
the load.

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Gear Pumps

• A gear pump uses the meshing of gears to pump fluid by displacement.

They are one of the most common types of pumps for hydraulic fluid
power application. There are 2 main variations, the external gears and the
internal gears. Gear pumps are fixed displacement, meaning they pump a
constant amount of fluid for each revolution.
• Theory of Operation
– As the gear rotate they separate on the intake side of the pump,
creating avoid and suction which is filled by fluid. The fluid is carried
by the gears to the discharge side of the pump, where the meshing of
the gears displaces the fluid. The mechanical clearance are small- on
the order of a thousand of an inch (micrometer).
 

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Types of Gear Pump

• External Gear Type

• Typical displacement up to 250 cbm/rev

• Typical pressure 250 bar
• Fixed displacement only
• Good speed range, limited indirect drive capability, simple multiple
assemblies
• Generally noisy
• Good contamination sensitivity
• Poor serviceability
• Compact, light weight
• Low cost

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Internal Gear Pump

• Typical displacement up to 250 cbm/rev

• Typical pressure 250 bar
• Fixed displacement only
• Good speed range
• Simple multiple assemblies
• Low noise
• Good contamination sensitivity
• Poor serviceability
• Good fluid compatibility

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Vane Pumps

• VANE PUMP
• A rotary vane pump is a positive displacement pump that consists of vanes
mounted to a rotor that rotates inside of a cavity. In some cases these
vanes can be variable length and/or tensioned to maintain contact with
the walls as the pump rotates.

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Fixed Vane Pump

• Typical displacement to 200 cbm/rev

• Typical pressure 280 bar
• Fixed displacement only
• Provides prime mover soft start
• Simple double assemblies
• Low noise
• Good serviceability

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Variable Vane Pump

• Typical displacement 100 cbm/rev

• Typical pressure 160 bar
• Simple multiple assemblies
• Low noise
• Low cost

• Piston Pumps
– Piston Pumps are positive displacement pumps that uses reciprocating
motion of pistons to create a flowing liquid. Basically there are 2 types
of piston pumps; axial and radial.

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Axial piston pump

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Fixed displacement axial piston pump n(in-line)

• Typical displacement 500 cbm/rev

• Typical pressure 350 bar
• Multiple assemblies possible
• High overall efficiency
• Compact package

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Fixed displacement axial piston pump (bent axis)

• Typical displacement 500 cbm/rev

• Typical pressure 350 bar
• No through shaft option ( multiple assemblies not possible)
• High overall efficiency
• Compact package

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Variable displacement piston pump

VARIABLE DISPLACEMENT PUMP (MAXIMUM FLOW)

VARIABLE DISPLACEMENT PUMP (NO FLOW)

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Variable displacement pump (REVERSE FLOW)

• Displacement 750+ cbm/rev

• Pressure capabilities 350/400 bar
• High noise level
• Sensitive to poor inlet condition and contamination
• High overall efficiency
• Good life expectancy
• Large, bulky units
• Good fluid compatibility
• High Cost
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BENT AXIS VARIABLE DISPLACEMENT PUMP

• Displacement 1000 cbm/rev

• Pressure capabilities 350 bar
• Suitable for open and closed loop
• High overall efficiency
• Good life expectancy
• Through shaft multiple assemblies not possible
• High cost
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RADIAL PISTON PUMP

• Displacement 250 cbm/rev

• Pressure capabilities to 350 bar
• Suitable for open and closed loop
• High overall efficiency
• Good life expectancy
• Short, wide shape
• Simple multiple pump assemblies
• High cost
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Pump Installation

• Lifecycle of a pump depend entirely on how it is mounted and how it is

used.
• Proper Installation procedure has to be followed especially when servicing
or installing new hydraulic pumps.
• In this topic the participants should be able to know some procedure
regarding pump installation and maintenance procedures.

Case
lubrication

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• When a hydraulic pump is opened for servicing, or a new pump is
installed, the case must be properly lubricated with the correct hydraulic
fluid.

• Filling oil to the case will introduce air, moisture to the system, to remove
the air, the vent or drain plug of the case must be open when filling it oil.
Air in the hydraulic system will cause a lot of damage than you think.

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 EXCESSIVE
PRESSURE PEAKS
(effect of air in the system)

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Pump Failure

• CAUTION:
• NEVER RUN A HYDRAULIC PUMP WITHOUT ANY OIL IN THE CASE, AS THIS
WILL LEAD TO PUMP DAMAGE!!!!

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Cavitation

• Cavitation means that cavities or bubbles are forming in the liquid that is
being pumped. These cavities form at the low pressure or suction side of
the pump, causing several things to happen all at once. 
– The cavities or bubbles will collapse when they pass into the higher
regions of pressure, causing noise, vibration, and damage to many of
the components.
– Loss of pump capacity
– Pump cannot develop the required head
– Pump efficiency will drop and later
• The cavities form because of vaporization, Air ingestion, Internal
Recirculation, Flow Turbulence and the Vane passing syndrome.

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Vaporization

• A fluid vaporize because of two reasons, when its pressure drops too low
or when its temperature gets too hot. All centrifugal pumps have a
required pressure head at the suction side of the pump to prevent
vaporization. In order to prevent vaporization, suction head must be
higher than the manufacturer required NPSH.
• How can we increase the suction head?
– Raise the liquid level in the tank
– Raise the tank
– Pressurized the tank
– Place the pump in a pit
– Reduce piping losses
– Install a booster pump
•  How can we lower the oil temperature?
– Injecting small amount of cooler fluid in the suction line
– Maintaining an efficient oil cooler

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 Cavitation due to clogged air breather Cavitation due to closed suction valve

Cavitation due to collapse hose Cavitation due to fluid temperature too cold

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 Cavitation’s due to long suction lines Cavitation due to many pipe bends
 

Cavitation due to low suction head Cavitation due to high revolution of prime
mover
 
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Air ingestion

• Air gets into the system in many ways;

– Through the packing, stuffing box, seals

– Through leaking flanges
– Through faulty maintenance procedure

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• Internal recirculation
– Internal recirculation is prevailing on negative displacement pumps,
since internal leakage is present. However, on positive displacement
pump, internal leakage is present when the seals are worn –out or
damage.
• Turbulence
– We always prefer to have liquid flowing the piping at a constant
velocity. Corrosion or obstruction can change the velocity of this
liquid, and any time you change the velocity of a liquid, you change its
pressure. 
• The vane passing syndrome
– This is prevailing on negative displacement pumps (centrifugal pumps).
There is a point where the impeller would pass its minimum and
maximum position, where low and high pressure area meets. Bubble
are created in the low pressure area, and then suddenly collapsed in
the high pressure region.
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Pressure Peaks

• Besides cleanliness rating and dirt-holding capacity, essential selection

criteria for filters are, of course, pressure and flow. However, other factors
are less obvious. Among the most overlooked of these are transient
(instantaneous) flow and pressure. Potentially damaging consequences
can result when a pump suddenly starts or stops or a valve shifts from
fully open to fully closed.  

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• One way to compensate for these inevitable flow and pressure transients
is to incorporate an open or closed surge tank into the circuit. An open
surge tank is used to accommodate excess flow and is similar to a hydro
pneumatic accumulator. However, the gas chamber is open to
atmosphere. A closed surge tank is similar, but it has a throttling valve to
regulate air flow to and from atmosphere. Closed surge tanks are used
primarily to absorb and smooth out pressure surges.
• Left unchecked, these pressure transients (spikes) travel like a wave from
their source and through a hydraulic line until they dissipate. When these
pressure waves encounter a rigid obstacle — such as a closed valve —
they can even be retransmitted back into the system, toward the source. If
this propagation and echo effect continues, system malfunctions can
occur, and components exposed to these pressure and flow variations can
undergo premature failure.

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Causes of Pressure Peaks

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Exercise on Hydraulic Pumps

• Filtration 
– Several methods are available to remove particulate contamination
and water from hydraulic fluids. The choice of method depends both
on the contamination level of the fluid and its specific area of
application. Heavily contaminated fluids are best cleaned by removing
them from the operating system and purifying them externally prior to
re-use. Subsequently, in-line particulate filters and water-absorbing
filters can provide contamination control.
– In this topic the participants should be able to identify the different
types of filters and their applications.

Oil filter
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Definition

• MICRONS
– It is a unit of measurement, equivalent to 1/1,000,000 of a meter.
– Contaminants
• Sources of Contaminants

B
uilt-in
dirt

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 Present in initial charge of oil

Introduced during repairs

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 Generated
in cylinder

Generated in pumps, valves etc

• Ingress through loose breather cap (keep tight, check filter element)
• Ingress of rest, paint flakes from tank
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Filters

• Types of Filters
– Suction line filter ( can filter up to 100-200 microns)

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Filters

• Pressure Line Filters ( can filter up to 5-10 microns)

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• Return line filter (can filter up to 20-40 microns)

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• Off Line Filtration

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• Filter Mounting

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ISO Cleanliness Code

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ISO Cleanliness Code

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 • THE ISO 4406 uses a three number system;
• FIRST NUMBER indicates number of particles greater than 4µm.
• SECOND NUMBER indicates number of particles greater than 6 µm.
• THIRD NUMBER indicates number of particles greater than 14 µm.

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Contamination Measurement

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Reservoir

• Introduction
– In fluid power, one of the requirement is to have a reservoir for
holding the fluid, aside from being a container, the reservoir serves
many more purposes.
– In this topic, the participants should be able to know the functions of a
reservoir.
• Definition
– RESERVOIR
– It is hollow vessel where fluid is kept for later use.
• Function
– To aid in expelling entrained air
– Cooling the hydraulic fluid
– Aids in removing contaminants
– Use as settling tank where heavy particles of contamination

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Design Aspects

• Tank capacity must be 3-4 times the lpm of the pump

• It should be on legs, not flush on deck ( to aid heat transfer and enable
complete draining)
• Baffle plate to be placed between return lines and pump suction line
• Breather cap to be fitted and tightly placed
• Sight glass/ level gauge to be kept clean and operational
• Level in the tank to be maintained 3” to 4” above the suction filter

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Types of Reservoir

• Pressurized
• Non-Pressurized

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Accumulators

• Accumulators
– On board ship, there is some hydraulic equipment that must be
operated in the event of a loss of power. In order to operate such
equipment, the system should a have reserve energy to perform such
operation. 
– In this topic the participants should be able to know the function of an
accumulator. The participants should also gain theoretical knowledge
on how to charge accumulator.
• Definition
• ACCUMULATOR
– It is an energy storage device. It is pressure storage reservoir in which
a non-compressible hydraulic fluid is held under pressure by an
external source.
• Function
– The accumulator in a hydraulic circuit should be placed as near as
practical to the source of shock or potential energy requirement.

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Function

• Normally the accumulator should be installed upward with oil connection

facing down. The hydraulic fluid must be kept free of foreign matter to
prevent damaging the accumulator wall. For maximum seal life, the fluid
should be filtered to 10 micron or less.

– To provide auxiliary power

• Several applications require an auxiliary power source to
supplement the pump flow. Instead of using a large pump to
generate a high power during a fraction of the cycle, a smaller
pump is used to spread power evenly over that cycle. 
– To provide emergency power
• Some applications require an alternate power source to return the
system to a safe status in case electrical power is lost.

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 – To provide leakage compensation
• Several applications require a cylinder to maintain position and
pressure during long standby periods. However, leakage losses and
temperature variations cause the pressure to slowly drop over
time. Accumulators can compensate for the decrease in pressure,
so the pump does not need to run continuously. 
– To provide shock suppression
• Sudden stoppage or reversal of high velocity oil causes high
pressure surges in a hydraulic circuit. These pressure increases, or
shocks, are caused by the inertia of oil when it stops quickly. The
accumulator cushions the oil by compressing the gas in gas-loaded
units or by compressing the spring in spring-loaded units.

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Types of Accumulator Accumulators

• Weight Loaded Accumulator

– It discharges a constant pressure but it is large and bulky.
• Spring loaded Accumulator
– It is less bulky compared to weight loaded but it discharges a varying
pressure.
• Gas Charged Piston type
– The pressure at which the oil is stored can be changed simply by
modifying the pre-charge pressure; it does not discharge at constant
pressure however. 
• Gas charged bladder type
– The most common type of accumulator used on hydraulic system on
board.
– It consist of a shell or case with a flexible bladder inside the shell. The
bladder is larger in diameter at the top (near the air valve) and
gradually tapers to a smaller diameter at the bottom. The synthetic
rubber is thinner at the top of the bladder than at the bottom.
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 – Barlow’s formula for hoop stress, which states: “The stress in a circle is
directly proportional to its diameter and wall thickness.” This means
that for a certain thickness, a large diameter circle will stretch faster
than a small diameter circle; or for a certain diameter, a thin wall hoop
will stretch faster than a thick wall hoop. 
• Diaphragm Type
– It is constructed in two halves which are either screwed or bolted
together. A synthetic rubber diaphragm is installed between both
halves, making two chambers
– It operates in a manner similar to that of the bladder-type
accumulator.

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Accumulator Safety

• The primary safety rule to follow when using an accumulator circuit is

ALWAYS have the accumulator COMPLETELY DISCHARGED before
removing it from the circuit. Never attempt to service or disassemble an
accumulator without special training and all proper tools. 
• The reason for this is that stored energy can throw parts with enough
force to cause injury or spray oil as fittings are loosened. 
– DO NOT weld or braze directly on the accumulator shell.
– DO NOT USE oxygen or air for pre-charging the accumulator.

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Accumulator Charging

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1. Isolate the accumulator from the system and make sure the hydraulic
fluid pressure is zero.
2. Remove gas valve protection guard and valve cap from accumulator.
3. Use only recommended charging tools and gauges. ( gauges must be
verified as working) Make sure that charging valve “A” is completely
turned counterclockwise.
4. On the 3 way valve, close the bleed (vent valve) and turn valve “A” fully
clockwise to open the non-return valve on the accumulator.
5. Open the Nitrogen bottle valve and charge the accumulator.
6. Some maker recommend that the pre-charged pressure is from 65-70%
of the system’s pressure.

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7. Once the pre-charge pressure is at the desired level, close the nitrogen
bottle, fully turn valve “A” counterclockwise and open the bleed valve
/vent valve.
8. Remove the charging hose and replaced the valve cap and protective
guard.
9. Accumulator is ready for use.

• NOTE:
• Allow accumulator to rest approximately 10-15 minutes after gas pre-
charging. This will allow gas temperature to adjust and equalize. This will
allow gas temperature to adjust and equalize. Recheck the gas pre-charge
pressure and adjust if necessary. Check the accumulator gas valve for any
leaks with soap and water.
• Pre-charge pressure should be checked periodically. System pressure must
be zero when checking the pre-charged

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Construction

• Industrial hose consists of an inner tube for conducting the fluid,

reinforcement for the inner tube and a cover layer to protect the
reinforcements.

• Nitrile ( Buta N) and Neoprene go into most tubes and cover stocks of
hydraulic hoses. Inner tunes of Butyl or ethylene propylene are usually
specified with fire resistant phosphate ester hydraulic fluid. Nylon,
however has found increasing acceptance and use because it does not age
or harden.

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Hose Fittings types may be either permanent or reusable.

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Maximum Hose Life

• Check the system for pressure spikes or surge. Make sure operating
procedures do not exceed 25% of hose rated minimum burst pressure. If a
bubble or bulges occur on a flexible hose, an internal leak is present, and
the hose should be replaced.
• High oil temperature (over 200 degree F, about 93 degrees Celsius) quickly
harden or stiffen the inner tube of the hose. When pressure pulses flex a
harden hose, it will fail and crack. As a rule of thumb 25ºF increase in
temperature reduces the hose life by 50%.

• Some manufacturers recommend exchanging exposed hydraulic hoses

every 5 years.

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Hose Installation and Maintenance

• The hose is to be fitted with a

little slack for movement while
working. A hose fitted too tight
may fail early.
• At bends provide enough hose for
a wide radius curve. Too tight
bends pinches the hose and
restricts the flow. The line could
even kink and close entirely. In
many cases, use of the right
fittings or adaptors can eliminate
bends or kinks.
• If a hose is installed with a twist
in it, high operating pressure tend
to force is straight. This can loose
the fitting nut or even burst the
hose at the point of strain.

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• When hose pass near a hot surface, they should be insulated by a heat
resistant boot or a metal baffle. In any application, brackets and clamps
keep hoses in place and reduce abrasion.

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• In applications where there is considerable vibration or flexing, allow
additional hose length. The metal hose fittings of course, are not flexible,
and proper installation protects metal parts from undue stress and avoids
kinks in the hose.

Application of Hydraulics on board ship

• Open discussion using a Steering gear simulator on the application of
hydraulics on board ship.

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