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Industrial Fluid Power (ME312)

Course Outcomes (COs):-
1. Explain fundamentals and applications of fluid power systems.
Unit 1
2. Draw and use different ISO/JIC conventions used in hydraulic and
pneumatic systems
3. Explain construction and working of hydraulic and pneumatic system
Introduction to
Fluid Power
elements.
4. Design hydraulic and pneumatic circuit for different applications
5. Use safety regulations and troubleshooting to solve problems found
in hydraulic and pneumatic systems.

Hydraulics: originates from Greek word “Hydra” which means water.

Introduction to Fluid Power
Water was used as a hydraulic fluid in earlier stages but is has some
 Fluid Power is the system that uses the energy of pressurized deficiencies.
liquid or gas from an energy generating source to an energy It freezes readily
use area to perform variety of tasks. It is a relatively poor lubricant.
Tends to rust metal components.

 Fluid power is technology that deals with generation, control,

and transmission of power using pressurized fluids. Pneumatics: derived from as Greek word “Pneumn” which means air.
Air is freely and abundantly available and can be readily exhausted into the
atmosphere after its task.
A fluid can be gas or liquid
 Fluid power system are designed specially to perform work. The work
 Hydraulics: is accomplished by a pressurized fluid bearing directly on an operating
Systems using pressurized liquid such as oil or water, synthetic fluid cylinder or motor.
oils as fluid  A fluid cylinder produces a force, where as fluid motor produces a
torque. Control components are needed to ensure that the work is
 Pneumatics: done smoothly, accurately, efficiently, and safely.
Systems using compressed air as fluid.

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Criteria Hydraulic Pneumatic Electrical Mechanical

Basic Elements of Fluid Power System Energy
Oil Air Electrons
Shafts, Levers,
Carrier wheels, Chains
Energy Energy Energy
Energy Energy Re- Air Engines and other
Conversion Storage Conversion Hydraulic Pumps Generators
Control Conversion Compressor prime mover
Element Element from mech.
Element Element
(Pump, (Accumulator Energy Pipes, Hoses, Pipes, Hoses, Electrical cables, Shafts, Gears,
(Valves) (Actuators)
Compressor) , reservoir) Transmission tubes,etc tubes,etc wire wheels, Belts.
Good for small Not good with
Energy Very good with Very good with
Energy Conversion Element (Pump, Compressor):- Mechanical energy into powers with heavy gearboxes,
Control various valves various valves
Fluid Energy. contractors/ relay levers, etc
Energy Re- Hydraulic cylinder Air cylinder and Wheel, chains,
Electric motors
Energy Storage Element (Accumulator, reservoir):- Store Energy by storing conversion and motors motors rams with crank.
itself and supplying it when the workload demands. Energy Limited with High with air Low in form of
Low in fly wheels.
Storage accumulator reservoir chargers, batteries
Energy Control Element (Valves):- Makes the form of energy adaptable to Force x disp.
Power terms Pressure x Flow Pressure x Flow Current x Vtg
the application by controlling pressure, flow and direction. Tor x ang disp
Good as no
Energy Re-Conversion Element (Actuators):- Re-converts the fluid pressure Low due to losses
transformation of
Efficiency in conversion and Fair to good. Good
energy again into mechanical energy in the form of required application. energy, only
valves.
frictional losses.

Advantages of Fluid Power Systems

Fluid Principles  Wide range of force and speed:- Due to its force multiplication nature, provides
widest range of force ranging from, mN to GN.
 Pascal's Law
 Precise motion with instant reversing:- Provides accurate and precise motion.
A fluid in a confined system or container exerts Forces and flows are instantly reversible. So FP is found as integral part of machine tools.
equal pressure in all directions.
 Ease of operation:- Control valves are simple and easy to operate than any other
systems (lever and linkages). This reduces fatigue and increases efficiency.

Bramah’s Press principle:  Flexibility:- Max flexibility without requiring complex mechanism. Wide range of speed and
feeds are achieved by adjusting small FCV. Different pressures in different parts of system is also
Utilization of Pascal's law to produce a large
achieved.
force by applying very small force on small area.
 Easy power transmission:- Power Can be easily transmitted through hoses, pipes, etc
( higher force magnification) as compared to shafts, gears, belts.

 Maintainability:- Low moving parts and self lubricating system.

 Space freedom:- Power source need not to be close to the application. In case of
pneumatic, one compressor can be used to run lot of applications.

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Basic Components of Hydraulic system

Limitations of Fluid Power Systems

 Lower overall efficiency:- Because of losses at two stages of conversion

as well as in pipes, valves, openings, etc considerably reduce the overall performance
of FP system compared to other.

 High cost:- Elements are costlier than others, because of the degree of
precision and accuracy required to manufacture them.

 Failure of pressure due to leakage of pressurized fluid

Basic Hydraulic Systems

Typical Lift / Ram Circuit

Cylinder
Relief Motion
Valve
Control
Valve
Cylinder

Pump

Filter

Tank Cooler

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Basic Hydraulic Systems

Typical Motor Power Circuit Basic Components of Pneumatic System

EH Servo
Control Valve

Hydraulic Blower
Motor Fan

Joystick

Variable
Pump

Filter

Tank Cooler

Industrial Applications
Applications of Fluid Power Systems

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Transports Applications

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Construction Applications Advantages of Hydraulic Systems

 Hydraulic power - easy to produce, transmit, store, regulate and control
and maintain.
 Lower weight to power ratio (8.5 kg/kW for electrical and 0.85 kg/kW for
hydraulic system)
 Possible to generate high gain in force and power amplification
 Uniform, smooth and step-less motion with variable speed and force
 Simpler and easy division and distribution of hydraulic power

 Less frictional resistance

 Hydraulic elements can be located at any place

 Minimal noise and vibration produced by pump

 Easy maintenance

 Mechanically safe and compact systems. Limitations/ Drawbacks

 Hydraulic output can be both linear, rotational or angular
 Higher manufacturing cost of hydraulic elements due to higher
 Hydraulic systems are better over load safe power systems
degree of precision in machining
 Absolutely accurate feedback of load, position
 Effect of exposure to unfriendly and adverse environmental
conditions

 Leakage – extremely serious concern

 Requirement of special treatment to protect against rust, corrosion,

dirt, etc.

 Fire hazards with petroleum oil at higher level of working

temperature.

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Parameter Hydraulic System Pneumatic System Parameter Hydraulic System Pneumatic System
10. Energy transmission Metal tubes, pipes/ hoses Flexible plastic tubing
1. Working media/fluid/ energy Oil, Water (incompressible elements
Air ( compressible fluid)
carrier fluid)
11. Cost Higher Lower
Medium to high up to 700 bar 12. Maintenance Complex and time consuming Easier and quicker. System is
2. Working pressure range Low – 7 to 10 bar
or even more than it neat and clean
13. Lubrication Self Lubrication Air Lubrication (Mixing oil with
3. Force developed/
Higher low to medium reservoir)
magnification obtained
13. Applications High load lifting, material Low cost automation
4. Accuracy and precision of Less accurate due to handling equipments,
Better ( very accurate)
motion of cylinder compressible nature of air. NC/CNC machine tools,
robots
5. Energy conversion element Pump Compressor

7. Size of system for driving the

compact Bigger dia. of piston
same load

8. Control of speed and feed of

Precise and very accurate Less accurate
actuator

9. Piston velocity Lower Higher

10. Energy transmission

Metal tubes, pipes/ hoses Flexible plastic tubing
elements

Units of Measurement:- Derived SI units:-

Basic SI Units:-  Force = mass x Acceleration = m x a

= kg x m/s2
= N
Physical Quantity Name of Unit Symbol
Length meter m
Units N Lb. kgf
Mass kilogram kg
N 1 0.2248 0.1020
Temperature Kelvin / Celsius k / °C
Time second s Lb. 4.448 1 0.4536
kgf 9.81 2.205 1

 Weight = mass x Grav. Acceleration = mxa

= 1 kg x 9.81 m/s2
= 9.81 N

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 Energy = Capacity of producing effect

 Pressure = Force per unit area = F / A = Joule
= 1 Pa = 1 N/m2 Other Units are Calories, Btu and kWh
Other Units are bar, PSI, Kg/cm2, MPA
Units Joules Cal Btu kWh
 Flow = m3 /sec
Joule 1 0.2389 9.48 x 10-4 2.78 x 10-7
Other Units are GPM (gallons per minute) , LPM (ltr per min)
Cal 4.187 1 3.97 x 10-3 1.163 x 10-6
Units Liters US Gal m3 Btu 1055 264.2 1 1
liters 1 0.2248 0.1020 kWh 3.6 x 106 8.60 x 105 3413 1
US Gal 3.785 1 3.785 x 10-3
m3 1000 264.2 1

 Viscosity  Work = Force x Disp

Dynamic Viscosity:- 1 poise = 100 centi-poise = 0.1Ns/m2 = N.m
Kinematic Viscosity:- 1 stoke = 100 centi-stoke = 10-4 m2/s 1 Joule = 1 Nm

 Power = Rate of doing work

= Work Done / Time  The pressure in the hydraulic system is the
= (Force x disp) / Time = Force x Velocity result of the opposing load
= N.m / s = watts.

Linear Power = Watts = J/s  In pneumatic systems the pressure regulator

Rotational Power = Torque x Ang. Velocity of FRL (Filter, Regulator and Lubricator) unit
Electrical Power = Voltage x Current
keeps the pressure of the system constant.
Fluid Power = Pressure x Flow
= N/m2 x m3/s
= N.m/s

Other Unit Horse Power and Kilowatts

1kW = 1.341 hp
1hp = 0.7457 kW

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Hydraulic Fluid and their Properties Service Properties or Performance

Characteristics of Hydraulic Fluid
 Functions of Hydraulic Fluid
1. Viscosity
1. Power transmission
2. Viscosity Index
2. Lubrication
3. Demulsibility
3. Sealing
4. Lubricity
4. Cooling
5. Oxidation Stability

6. Air separating ability

Viscosity  Practical
units of absolute viscosity
 Measure of internal resistance of fluid to flow ºE: Degree Engler in Germany & continental Europe
RS : Redwood seconds in U.K.
 Absolute / Dynamic Viscosity: SUS: Say bolt Universal seconds in USA
Force required to move a flat surface of unit area at given
velocity gradient.
ºE: ratio of time to pass 200 gm of oil at its operating
Unit of dynamic viscosity: Poise
temperature through Engler viscometer to time to pass
1 Pa sec = 10P
200 gm of distilled water at 20 º C.
1 P = 100 centipoise

RS: time in seconds to pass 50 cc of oil at its

 Kinematic Viscosity:
temperature through a std Redwood viscometer
Liquid flows out in a viscometer under its own weight so
density is considered
Kinematic Viscosity = Dy. Viscosity / Density SUS: time in seconds to pass 60 cc of oil at 100º F
Unit of dynamic viscosity: m 2/s through a std aperture of Say bolt viscometer
1 stoke= 10-4 m2/s 1cST= 10-6 m2/s

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 If Viscosity is High  ISO Viscosity Grade

High resistance to flow, causes sluggish operation SAE (Society for Automotive Engineers) standardized automotive
oils and gear oils on the basis of viscosity.
Increased power consumption due to frictional losses.
Min cST at Max cST at
SAE VG cP at -18°C
Increased pressure drop 100°C 100°C
High temperature caused by friction 10W 2500 4.1
20W 5000 5.6
20 5.6 Less than 9.3
 If Viscosity is Low 30 9.3 Less than 12.5
Increased Leakage losses 40 12.5 Less than 16.3
Excessive wear due to breakdown of the oil film between 50 16.3 Less than 21.9
moving parts. Industrial oils are classified as per ISO 3448.
These defines 18 VG in the range of 2 cST to 1500 cST @ 40°C.

Before ISO classification IOC was using oil grades as per their own
standards. These hydraulic oils were being designated as servo
system (SS) 311 ,SS311 etc. There grades are also provided with
new VG No.

ISO Viscosity Grade Kinematic Viscosity cST @ 40°C

ISO VG Min. Max. 2. Viscosity Index
2 1.98 2.42 Temperature dependent characteristic of oil is expressed
3 2.88 3.52 with the help of term of viscosity Index
5 4.14 5.06  Rate of change of Viscosity with temperature is defined as
7 6.12 7.48 Viscosity Index (VI)
10 9 11.0  Effect of temperature on the viscosity of oil:
150 135 165
220 198 242
680 612 748
1000 900 1100
1500 1350 1650

IOC No. Old New VG

Servosystem 311 Servosystem 32
Servosystem 314 Servosystem 46
Servosystem 526 Servosystem 121

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How to select a Hydraulic Fluid with Correct Viscosity Index (V.I.)?

 Effect of operating pressure on the viscosity of
oil:

SSUg = SSU Viscosity of Gulf coast

crude Oil at 100°F (0-VI)

SSUp = SSU Viscosity of Pennsylvania

crude oil at 100°F (100-VI)

SSUo = SSU Viscosity of oil at 100°F

Oil with Higher VI will exhibit minimum change in

viscosity over a wide range of temperature and vice-
versa.

3. Demulsibility 4. Lubricity
The service property of fluid which enables it to
 Role of hydraulic oil as lubricant
separate rapidly and completely from moisture and to
successfully resists emulsification is called Demulsibility.  Additives added to improve the lubricity:
 Addition of water into oil results: Organic Chemicals.
 Lower lubricating value and sealant properties.

Reduction in service life of working surfaces.

 Additive used: Emulsifiers

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5. Oxidation (Chemical Stability)

6. Air separating ability:-
 Oxidation stability is the fluids ability to resist oxidation
Foaming is resulted due to entertainment of air in oil.
and chemically changes that appear in the fluid for long
Ability to dissolve air in oil increase with increased in
periods.
pressure.
 Rate of oxidation rises rapidly with increase in
if drop of pressure occurs, the dissolved air emerges out
temperature of oil
in the form of bubble.
 Result of oxidation: formation of sludge, gums,carbon in This undissolved air, which is visible as foam can lead
oil to cavitation in pumps and valves.
 Additives used: Anti-oxidants

Requirements of Good Hydraulic Fluid

 Should have pour point well below the
 Moderate viscosity minimum operating temperature
 High demusibility
Should have flash point well above the
 Good lubricity/ lubricating value
maximum operating temperature
 Should remain chemically stable over expected
 Good filterability
period of service
 High boiling point
 Good air-separating abilities (resistance to foaming)
 Non corrosive action to metallic parts of the system  Minimum toxicity

 Compatible with non-ferrous metals and seals in  Pleasant smell

hydraulic system

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Types of Hydraulic fluids 1. Petroleum Oils

1. Petroleum oils  Commonly used hydraulic fluids
 Characteristics of oil depends on:-
2. Water
Type of crude oil used
3. Synthetic fluids Degree and method of refining
Chemical treatment given
4. High water based fluids (HWBF) or high
 Commonly used are paraffin base oil, Naphthenic or
water content fluids (HWCF) Gulf coast base oils or mixture of both
5. Fire resistant oils Additives added: Antifoam agents
Rust inhibitors
Oxidation stabilizers

2. Water
Advantages: Advantages:
 Excellent protection against rust  Viscosity does not changes very much (1.5 cST @40°F)

 Better sealing property  Very low cost

 Better heat dissipation capacity  Does not catch fire

 Chemically stable for long time

 Does not make shop floor slippery if it leaks

Disadvantages / Drawbacks:

Flammable (not used in coal mines, die casting Disadvantages:

industries because of chances of fire. )  Used over limited range of temperature

 Dose not possesses lubricating property

 Highly corrosive in action and forms rust

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3. HWBF or HWCF Advantages:

Referred as : 95/5 or 90/10,  Flash point : 150º C

95 % or 90 % water and 5 % or 10 % additives  Good cooling characteristics

e.g. 1. Soluble oil Cutting fluid  Cleanliness- easy to handle and can be flushed
using ordinary sewage disposal system
2. Micro emulsion
 Viscosity remains constant
3. Thickened Micro emulsion
 Less costly
4. Water Glycols
 Cost of transportation is less

Important Additives used:

Disadvantages / Limitations:
 Anti Foaming
 Corrosive in nature
 Anti Wear
 Special care needs to be taken to reduce  Corrosion inhibitor
oxidation  Emulsifier

 Lubrication
 More tendency to foam
 Bacterial Prevention
 Evaporation  Deionisation

 Oxidation Inhibitor

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4. Synthetic Fluids 5. Fire Resistant Oils

Laboratory synthesized chemicals
e.g. 1. Phosphate Esters Classification:-
2. Chlorinate hydro-carbons HF-A:- contains 80% of water.
Do not contain any water or volatile material
HF-B:- This is water-in-oil emulsion containing petroleum
Advantages:
oil, water emulsifiers and additives
 Non flammable so fire resistant
 Suitable for high temp. and high pressure applications HF-C:- Water- Glycols and other additives.
 Less tendency of sludge or gum formation
HD-D:- Synthetic fluids are nonwater type e.g. phosphate
Disadvantages:
or blends of phosphate with petroleum oil.
 More Costly
 Not operate at low temperature so additional oil heaters are
added in tank.

Common Fire Resistant Oils Factors Influencing the Selection of Hydraulic fluid
 Operating pressure of the hydraulic system
1. Water in oil emulsion: water : 40 %, oil : 60 %
 Operating temperature of the hydraulic system
Water is dispersed in the form of tiny particles of size varying ¾ to
2 microns. In case of fire water forms steam acts as a blanket  Operating environmental conditions
cutting off the oxygen supply to the oil and prevents propagation  Cost of the fluid
of flame.
 Availability of the replacement fluid
2. Water glycol solution:
 Contamination possibilities
water : 40 %, poly glycols: 60 %  Compatibility of seals and other metallic parts of

3. Phosphate Esters : used above 150º C system with hydraulic fluid

 Safety to operators
 Expected service life of the fluid

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Castrol:
 Excavator Fluid : TH- 46 (premium hydraulic
fluid for construction equipments)
 Castrol High Spin EP: Anti wear Hydraulic
oils No. 32, 68

HPCL:
Super duty brake fluid: Dot-3(heavy duty
applications)

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Fluid Storage Element:- Types of Reservoir:-

Functions of Reservoir:-  Pressurized Reservoirs
 Storage of oil.  Non- Pressurized Reservoirs
 Cooling of oil a) Open Type

 Expansion of fluid b) Closed Type

 Separation of contaminants

 Structure support

 Easy access

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Hydraulic Power Pack:-

Fluid Reservoir:-

 Suction and return line

 Filter Spout, Air Breather
 Oil Level Display
 Baffle Plate
 Oil Drain Trap
 Inspection Cover and cleaning opening
 Tank Cover

Hydraulic Fluid Conditioning

About 95% of all hydraulic problems are cause
 Process of controlling the contaminants and
by heat, assembly, and contamination.
temperature of hydraulic fluid

 What is contaminant?

Any foreign particle/material/substance  Heat problems are generally a design problem.

present in the hydraulic fluid that has a  Assembly could be improper hose installation.
deteriorating effect on the performance of the  Contamination is everyone’s concern.
hydraulic fluid

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Common contaminants are:  Effect of contamination:

 Water vapor causes rust formation on reservoir walls.
 Particulate matter (metallic, fibrous, elastomers)
 Wear debris adds to the system contamination, which
 Water
in turn generates additional contamination. This is
 Air called as chain reaction of abrasive wear.
 Chemical reaction product – sludge  Blockage of flow passages and valve openings

 Other (non-compatible) hydraulic fluids  Jamming of cylinder pistons and valve spools

 Greater and uncontrollable leakage and loss of fluid

 Alterations in the control characteristics of system

 Component or system failure.

Sources of Hydraulic Fluid Contamination Contaminants during assembly stage:

 Pipe scales from uncleaned pipes before
1. Built in
assembly
e.g. Metal chips, welding scales, lapping compound,
 Corrosion or rust from stored ferrous components
sand from casting, debris from manufacturing
 Residue sand on the casting in foundry (valve
2. System generated bodies)
e.g. wear particle, sludge, Elastometric Particles  Lints / fabric threads or fibres from clothes used
3. Maintenance generated for plugging or cleaning of the system
components
e.g. Contaminants generated during system
 Swarf- produces by incorrect assembly tools or
maintenance, refilling of oil.
techniques.

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Ingress of Contaminants during Operation: Damage due to solid Contaminants:

 Addition of solid contaminants due to wear

 Old paint flakes

 Sludge generated due to oxidation

 Ealstomers particles produced by wear of

seals, packings, gaskets and

 air-borne particles

Hydraulic Oil Filters 1. Surface filters:

 Filters and strainers: Particulate contaminants  Use of screens / pored paper which cleans the oil
controlling elements passing through their pores

 Screen thickness is very thin and dirty unwanted

 Types of filters:
particles are collected on the top surface of the screen
Classification on the basis of type of filtering
element used
1. Surface filters 2. Depth Filters
2. Depth filters
 Thick walled filtering element

 Higher contamination arresting capacity than surface

filters

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How the filters are rated? / How to select the 3. Beta (β) rating:
filter for hydraulic system?
 Beta ratio is the indices of the efficiency of the
1. Nominal rating:
contaminant removal from the fluid flowing
 Micron reading indicated by the manufacturer.
through the filter element
Nominal rating 10m is supposed to trap 95% of
 Beta rating is the measure of the filter
entering particles greater than 10m in size.
performance indicating to what extent the
2. Absolute rating:
particles greater than the micron rating of the
 Indicates the largest opening in the filter element thus
filter in the incoming fluid are removed by the
indicates the largest size particle which will pass
filter
through the filter.

 Beta Ratio (βx) is the ratio of No. of Particles Upstream ( x) to the Ex. Determine the Beta rating of a given filter when
No. of Particles downstream ( x)
during test operation, 30000 particles grater then 20 μm
Assume System requires 10m level.
enter the filter and 1050 of these particles passed
No. of Particles Upstream ( x) = 15000
through the filter. What is the filtration efficiency?
No. of Particles downstream ( x) = 200
Β10 = 15000/200 = 75
Beta Efficiency= 1- (1/ βx)
For Β10= 75……. Efficiency is 98.5%
Β10= 75 indicates that 98.5% of particles larger than 10
m would be trapped by the filter.

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Construction and Working of oil Filter Location of Filters in Hydraulic System

Heat Exchangers in Hydraulic Systems Seals

Leakage:
Internal and External

Functions:
 Control of external or internal leakage of fluid

 Prevent entry of solid contaminants into the system

 Maintain Pressure

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Classification of Seals Static and Dynamic Seals:

According to
1. Method of sealing:- Positive and Non Positive

2. Area of application:- Static and Dynamic

3. Geometric shape:-

O Ring, Quad Ring, V Ring, T Ring, U Ring..etc

On the basis of Geometric shape:

Factors Influencing Selection of Seal

 Operating pressure & its Range

 Environmental conditions

 Operating temperature of the system

 Working fluid

 Application of seal such as static or dynamic

 Expected operational reliability

 Expected life of system

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Important Desirable Properties of Sealing Material Seal Materials

 Hardness  Metals
 Leather
 Change in volume:- Swelling and shrinkage  Asbestos
 Compression set  Elastomers, Rubber, Synthetic Rubber

 Tensile strength
Compatibility of seal with Fluids:
 Squeeze

Causes of Seal Failure Fluid Conductors

 Incorrect installation
 Worn out shafts Types of fluid lines:
 Vibrations generated due to bent shafts, imbalance of 1. Rigid pipes (metal Pipes)
reciprocating and rotary components
 Excessive side loads on piston rods 2. Semi rigid pipes (tubings)
 Extremely high or low operating temperatures
 Neglected oil leakage
3. Flexible pipes (Hoses)
 Improper speed of piston stroke
 Squeeze
 Improper lubrication
 Exposure to excessive temperature difference
 Contaminant deposition on the seal surfaces
 Abrasion of seal

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1. Rigid pipes 2. Semi-rigid pipes

 High strength steel pipes
 Steel tubes
 Wrought iron pipes
 G.I. Pipes  Copper tubes

 Aluminum tubes
Schedule No.
 Brass tubes
 Schedule 40 : Standard (STD)
 Schedule 80: Extra strong (XS)
 Schedule 160: Double Extra strong (XXS)

Flexible Hoses
Construction of Hose
 Flexible connections between moving
hydraulic components located at distant places
Advantages:
 Flexible
 Excellent ability to sustain shocks and
vibrations
 Easy for assembly and dismantle
 Manufacturing in very large length is possible
 Adopted for high pressure applications

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Factors Affecting Selection of Hoses

 Working pressure of the system

 Operating temperature
 Ambient temperature variations (if any)
 Flow carrying capacity
 Length of hose for avoiding sag or stretching
 Extent of vibrations and shock present in the
system
 Solid contaminants

Tube Fittings

Flare less fitting

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