HYDRAULIC / PNEUMATIC
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2 HYDRAULIC / PNEUMATIC JOSEPH J. PANDOLFO N.A.A.R.S.O joeboy@ptd.net /7/2017 NAARSO 2
3 1/7/2017 NAARSO 3
4 BEFORE YOU DO ANYTHING ON OR WITH A PNEUMATIC/HYDRAULIC SYSTEM DO THE FOLLOWING!!! 1/7/2017 NAARSO 4
5 1/7/2017 NAARSO 5
6 LOCK OUT/TAG OUT DE ENERGIZE IT BLEED IT OFF KILL IT DEAD. OR IT WILL KILL YOU!!! 1/7/2017 NAARSO 6
7 1/7/2017 NAARSO 7
8 WHAT IS IT? 1/7/2017 NAARSO 8
9 NOT WHAT YOU THOUGHT. 1/7/2017 NAARSO 9
10 ANSI NFPA/JIC T ISO /7/2017 NAARSO 10
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13 1/7/2017 NAARSO 13
14 A high-pressure jet that sprays hydraulic oil constitutes a physical danger and an environmental problem 1/7/2017 NAARSO 14
15 1/7/2017 NAARSO 15
16 HYDRAULIC SYSTEM: OIL FROM A TANK FLOWS THROUGH A TUBE OR PIPE,INTO A PUMP. THE PUMP INCREASES THE PRESSURE OF THE OIL. THE OIL IS MOVED TO A CYLINDER MOVING A PISTON,THERE BY DOING A JOB OR MOVING A LOAD. 1/7/2017 NAARSO 16
17 PNEUMATIC SYSTEM AIR FROM THE ATMOSPHERE IS PULLED INTO AN AIR COMPRESSOR. THE COMPRESSOR INCREASES THE PRESSURE OF THE AIR IT IS DISCHARGED TO A PISTON MOVING IT TO DO A JOB,OR MOVE A LOAD. 1/7/2017 NAARSO 17
18 BIG OR SMALL THE RE ALL THE SAME. FLUID SYSTEM OIL PUMP/AIR COMPRESSOR A DEVICE EITHER A PISTON OR A ROTATING MEMBER DRIVEN BY THE FLUID. PIPING AND CONTROLS 1/7/2017 NAARSO 18
19 PRESSURE; FORCE PER UNIT AREA [POUNDS PER SQUARE INCH] 1/7/2017 NAARSO 19
20 Pressure Gage 1/7/2017 NAARSO 20
21 PRESSURE 1/7/2017 AND TEMPERATURE NAARSO 21
22 1/7/2017 NAARSO 22
23 The HYDRAULIC system 1/7/2017 NAARSO 23
24 1/7/2017 NAARSO 24
25 prime mover 1/7/2017 NAARSO 25
26 FLUID PUMP MECHANICAL ENERGY IS CONVERTED INTO FLUID ENERGY 1/7/2017 NAARSO 26
27 hydraulic (pressure) energy 1/7/2017 NAARSO 27
28 FLUID MOTORS FLUID ENERGY IS CONVERTED TO MECHANICAL WORK. 1/7/2017 NAARSO 28
29 1/7/2017 NAARSO 29
30 ACTUATORS DEVICE THAT CONVERTS FLUID ENERGY TO MECHANICAL 1/7/2017 NAARSO 30
31 1/7/2017 NAARSO 31
32 PARTS OF THE SYSTEM PUMP OIL RESERVOIR INTAKE FILTER PRESSURE GAGE RELIEF VALVE OUT PIPING 1/7/2017 NAARSO 32
33 HYDRAULIC SYSTEMS PUMPS 1.GEAR-TYPE 2.VANE-TYPE ROTARY PISTON-TYPE 4.RECIPROCATING PISTON 1/7/2017 NAARSO 33
34 HYDRAULIC FLUIDS 1.PETROLEUM-BASE FLUIDS 2.SYNTHETIC-BASE FLUIDS 3.WATER 1/7/2017 NAARSO 34
35 FUNCTION OF FLUID 1.TRANSMISSION OF FLUID POWER 2.MEANS OF LUBRICATION 3.ACTS AS SEALANT 1/7/2017 NAARSO 35
36 TYPES OF 1.PENNSYLVANIA/PARAFFIN-BASE OILS 2.GULF COAST/NAPHTHENIC&ASPHALTIC 3.MIDCONTINENT/MIXED-BASE OILS CONTAIN BOTH NAPHTHENIC &PARAFFIN 1/7/2017 NAARSO 36
37 1/7/2017 NAARSO 37
38 SYNTHETIC-BASE FIRE RESISTANT SLUDGE/GUM REDUCED LITTLE EFFECT ON TEMPERATURE 1/7/2017 NAARSO 38
39 DIRECTIONAL CONTROL VALVES FUNCTION OF VALVE IS TO DIRECT OIL OR AIR TO A GIVEN PLACE IN A SYSTEM. 1/7/2017 NAARSO 39
40 TYPES OF VALVES TWO WAY TWO PORTS/TWO PASSAGES THREE WAY THREE PORTS/THREE PASSAGES FOUR WAY 4/4 1/7/2017 NAARSO 40
41 MANUAL CONTROL BY HAND OR FOOT/BODY PART MECHANICAL OPERATION CAM/ROTARY-SWING-TRIP PIN ELECTRICAL OPERATION MOTOR/SOLENOID 1/7/2017 NAARSO 41
42 PRESSURE CONTROL FUNCTION OF TO CONTROL PRESSURES IN THE FLUID POWER SYSTEM. 1.RELIEF VALVE 2.REDUCING VALVE 3.SEQUENCE VALVE UNLOADING VALVE 1/7/2017 NAARSO 42
43 FLOW CONTROLS FUNCTION OF TO CONTROL THE VOLUME OF FLUID THAT PASSES`A CERTAIN POINT IN A CIRCUIT. USED TO CONTROL SPEED 1/7/2017 NAARSO 43
44 MANUAL CONTROL BY HAND OR FOOT/BODY PART MECHANICAL OPERATION CAM/ROTARY-SWING-TRIP PIN ELECTRICAL OPERATION MOTOR/SOLENOID 1/7/2017 NAARSO 44
45 TYPES OF 1.METERING-IN 2.METERING-OUT 3.METERING BOTH DIRECTIONS 4.BLEED OFF 1/7/2017 NAARSO 45
46 ACCUMULATORS STORAGE DEVICE BATTERY CHEMICAL TO ELECTRICITY PIPE WITH CAP ACTS AS A CUSHION 1/7/2017 NAARSO 46
47 1/7/2017 NAARSO 47
48 HYDRAULIC ACCUMULATORS 1.SHOCK ABSORBER 2.OIL MAKE UP 3.COMPENSATE FOR LEAKAGE 4.SOURCE OF EMERGENCY POWER 5.STEADY DELIVERY PRESSURE 6.TRANSFER BARRIER BETWEEN OIL AND OTHER FLUID 1/7/2017 NAARSO 48
49 TYPES OF 1.WEIGHT-LOADED 2.SPRING-LOADED 3.AIR OR GAS NONSEPARATOR/SEPARATOR[DIAPHRAGM] 1/7/2017 NAARSO 49
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51 1/7/2017 NAARSO 51
52 TYPES OF CYLINDERS; 1.SINGLE -ACTING 2.SPRING -RETURN 3.DOUBLE-END 4.TANDEM 5.DUPLEX TWO PISTONS/ROD INSIDE 1/7/2017 NAARSO 52
53 ROTATING & NONROTATING CYLINDERS 1/7/2017 NAARSO 53
54 safety valve n. A valve in a pressure container, as in a vessel, that automatically opens when pressure reaches a dangerous level. An outlet for the release of repressed energy or emotion. 1/7/2017 NAARSO 54
55 Safety valve 1/7/2017 NAARSO 55
56 The PNEUMATIC system 1/7/2017 NAARSO 56
57 1/7/2017 NAARSO 57
58 AIR COMPRESSORS 1.POSITIVE-DISPLACEMENT/PRESSURE 2.VELOCITY/DYNAMIC 1/7/2017 NAARSO 58
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60 PARTS OF SYSTEM; AIR INTAKE AFTERCOOLER WATER SEPARATOR AIR RECEIVER AIR DISHARGE 1/7/2017 NAARSO 60
61 Air Receiver 1/7/2017 NAARSO 61
62 Aftercooler Filter, Regulator, Lubricator 1/7/2017 NAARSO 62
63 PNEUMATIC MOTOR 1.ROTARY 2.RECIPROCATING 1/7/2017 NAARSO 63
64 AIR FILTERS REMOVE ALL FOREIGN MATTER REGULATORS REDUCES OR REGULATES PRESSURE LUBRICATORS STORES OIL INJECTS OIL MIST OR FOG 1/7/2017 NAARSO 64
65 AIR FILTERS,REGULATORS, LUBRICATORS 1/7/2017 NAARSO 65
66 PIPING 1.RIGID 2.SEMI-RIGID/TUBING 3.FLEXIBLE/HOSE 1/7/2017 NAARSO 66
67 Hose Routing Replacement hoses must be restrained, protected, or guided (using clamps), to minimize risk of damage due to excessive flexing and whipping. 1/7/2017 NAARSO 67
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72 Flared tube 1/7/2017 NAARSO 72
73 THE BAD GUYS DIRT HEAT MISAPPLICATION IMPROPER FLUIDS FAULTY INSTALLATION MAINTENANCE 1/7/2017 NAARSO 73
74 THE SAFE WAY IS THE ONLY WAY! 1/7/2017 NAARSO 74
75 A pressure vessel a closed, rigid container designed to hold gases or liquids at a pressure different from the ambient pressure. 1/7/2017 NAARSO 75
76 other examples of pressure vessels are: diving cylinder, recompression chamber, distillation towers, autoclaves nuclear reactor vessel, habitat of a space ship, habitat of a submarine, pneumatic reservoir, hydraulic reservoir under pressure, rail vehicle airbrake reservoir, road vehicle airbrake reservoir and storage vessels for liquefied gases such as ammonia, chlorine, propane, butane and LPG 1/7/2017 NAARSO 76
77 How about now? 1/7/2017 NAARSO 77
78 1/7/2017 NAARSO 78
79 Date of years old? 1/7/2017 NAARSO 79
80 VARIOUS TYPES OF CORROSION ATMOSPHERIC GALVANIC UNIFORM/GENERAL PITTING STRESS CORROSION CRACKING CREVICE CORROSION HIGH TEMPERATURE 1/7/2017 NAARSO 80
81 A RECIPE FOR RUST " Take 2 parts iron (FE). Combine with 3 parts Oxygen (O). Add water and salt to taste. Increase temperature to speed up process. 1/7/2017 NAARSO 81
82 1/7/2017 NAARSO 82
83 QSI Training Services, Inc /7/2017 NAARSO 83 all rights reserved
84 MOTOR 8 QSI Training Services /7/2017 NAARSO all rights reserved 84
85 RELIEF Valve QSI Training Services, Inc /7/2017 NAARSO 85 all rights reserved
86 Some other IMPORTANT Components DRY Nitrogen Oil Bladder Accumulator Check Valve Flow Control Valve 8 QSI Training Services /7/2017 NAARSO all rights reserved 86
87 Filter or Strainer 1/7/2017 NAARSO 87
88 Pneumatics: Symbols 1/7/2017 NAARSO 88
89 HOSES AND THINGS
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92 Notice the hose coming off the top of the pump and going into the filter. It is bent in two planes. Most hose-specification literature recommends that hose not be bent in more than one plane. Doing so can cause uneven distribution of tension to reinforcing wires within the hose. As pressure pulsations occur in the hydraulic system, the overloaded strands undergo excessive tensile stress. After continuous cycling, the over-stressed strands can fail due to fatigue and eventually cause the hose to rupture. Worse yet, the failure can be catastrophic in nature, providing little or no warning of the impending failure. 1/7/2017 NAARSO 92
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94 PIPING FAILURES PRESSURE TOO HIGH. NOT PROPERLY SUPPORTED INCORRECTLY SIZED. TOO SMALL. HARDENING OF COPPER TUBING. 1/7/2017 NAARSO 94
95 DEFINITION OF AN INDUSTRIAL HOSE An industrial hose is a flexible reinforced tube for conveying liquids, solids, and gases. A typical industrial hose is dragged, coiled, run over, kinked and subjected to all kinds of abuse. Therefore, the application and its environment must be taken into consideration for proper hose selection. Selection of the proper hose and materials will increase hose life, improve performance, and ensure safety. Industrial hose is used for three purposes: 1. To transfer gases, liquids, solids and mixtures of these materials. 2. As a flexible connector to absorb surges and vibrations. 3. As a conduit to protect other hose, pipes and wires. 1/7/2017 NAARSO 95
96 Three Basic Elements of a Hose Tube Its purpose is to handle specific fluids or solids. It is the innermost rubber or plastic component of the hose that must be resistant to the material that it is intended to convey because it is the part of the hose in contact with the material. A variety of compounds can be used depending on the 1/7/2017 NAARSO 96 application.
97 Reinforcement Its purpose is to withstand a specific amount of working pressure measured in pounds per square inch (psi) or Pascal (Pa) or vacuum (In Hg, inches of mercury). The reinforcement may consist of many layers of fabric, yarn or wire placed on top of the tube and referred to as plies. 1/7/2017 NAARSO 97
98 Cover Its primary purpose is to protect the tube and reinforcement from external factors such as ozone, weather, abrasion and heat. A variety of compounds can be used, depending on the application. 1/7/2017 NAARSO 98
99 Caution! 1. Hose should not be used in out-of-sight applications, where the hose is buried, encased, or submerged.use rigid pipe in those applications. 2. Hose has a finite service life and is not to be used in permanent applications. 1/7/2017 NAARSO 99
100 P R O P E R H O S E S E L E C T I O N Proper hose selection is the first step in preventive maintenance. Selecting the best product for the application will allow you to obtain the maximum life expectancy from the product for the best value. 1/7/2017 NAARSO 100
101 S - Size: I.D. (Inside Diameter) O.D. (Outside Diameter) Based on the machinery sizing. Flow rate requirements (GPM for liquids; CFM for gases). 1/7/2017 NAARSO 101
102 T - Temperature: Consider exterior and interior temperature, as well as temperature impact on the material being conveyed. 1/7/2017 NAARSO 102
103 A - Application: Where will the hose be used? How will the hose be used? How often will the hose be used (continuous, intermittent, seldom)? What are the environmental conditions? Special hose construction (crush resistant)? Conductivity requirements? Is the hose used in a critical application? Government or Industrial Standard requirements? Use hoses that are specifically designed for these applications: Steam LP Gas Aircraft Ground Refueling Corrosive Chemicals 1/7/2017 NAARSO 103
104 M - Material Chemical name(s) and state(s) - (liquid, solid or gas) Food Dry or powder Liquid 1/7/2017 NAARSO 104
105 P - Pressure What is the working pressure? What is the maximum surge pressure? Is there a vacuum? 1/7/2017 NAARSO 105
106 E - End requirements What type of thread ends? Proper Coupling Selection? 1/7/2017 NAARSO 106
107 H O S E I N S P E C T I O N S Periodic Inspections Planning for Safety and Maximum Performance 1/7/2017 NAARSO 107
108 Achieving safety and performance in the use of a hose requires periodic inspections of the hose and its fittings prior to, during and after use. Hoses that have become old, worn, or damaged can present a danger to individuals and to the environment. Hoses that are not properly maintained can fail which may result in costly material spills, cleanup, downtime and injury. Planned inspections, corrective actions, and hose replacements can be less expensive than replacement or repairs made after a failure occurs. 1/7/2017 NAARSO 108
109 When and how often should you inspect hose? Inspection requirements will vary with each application type. The following factors should be considered: Critical nature of application Operating temperatures Operating pressures Environmental factors 1/7/2017 NAARSO 109
110 It is helpful to think of hose inspection at two levels: 1/7/2017 NAARSO 110
111 Level 1 Inspection An inspection of hose on an on-going daily basis looking for signs such as: 1/7/2017 NAARSO 111
112 1. Hose cover damage. Cuts, cracks, abrasion, exposed reinforcement, etc. 2. Stiffness or hardness of the hose. As a hose ages and is exposed to sunlight, ozone, extreme temperatures or chemicals it can lose some of its resiliency and become stiff and hard. When flexed, a stiffened hose can crack, leading to a failure. 1/7/2017 NAARSO 112
113 3. Changes in color. May indicate chemical attack. Ozone or aging. 4. Cover blisters. Chemical incapability. Permeation in the early stages of leakage. The blister can break and expose reinforcement that can degrade from contact with environmental factors. 1/7/2017 NAARSO 113
114 5. Kinked or flattened hose. Restricted material flow and hose performance. 6. Leakage. Puddles or spilled material under the hose assembly. Problem with coupling interface or attachment. Weeping from the hose. 1/7/2017 NAARSO 114
115 7. Damaged hose reinforcement. Weakened hose. 1/7/2017 NAARSO 115
116 Level 2 Inspection An inspection that requires equipment shutdown in order to conduct a more thorough evaluation of the hose in a safe manner. 1/7/2017 NAARSO 116
117 1. Visually inspect for leakage. NEVER inspect a hose for leaks by running your hand over it while it is under pressure or contains the material being transferred. Escaping fluid under high pressure can exert enough force to penetrate and cut flesh, causing painful and severe injury. Hot materials and chemicals can cause serious burns. ALWAYS conduct close inspection of hose when pressure is released and the hose does not contain potentially dangerous material. 1/7/2017 NAARSO 117
118 2. Hydrostatic Pressure Testing Test at regular intervals. Essential for hoses used in hazardous applications such as chemical, steam, petroleum and compressed gas transfer. Always use water for pressure testing. Never use flammable or corrosive fluids or compressed gas 1/7/2017 NAARSO 118
119 RMA HYDROSTATIC TESTING PROCEDURES All hose and couplings should be hydrostatic tested at regular intervals. Intervals for testing vary with each hose type. Procedure: 1. The hose should be at room temperature. 2. The testing area should be clean and dry. 3. Lay the hose out straight to its full length. 4. Place the hose on rollers. This allows the hose to be moved while under pressure. 5. Restrain the hose if there is danger of uncontrolled movement during the test. 6. Conduct a visual inspection. Look for cuts, gouges, bulges, soft spots, coupling slippage or any signs of wear or failure. 7. A hose which does not pass a visual inspection should be replaced. 8. A hose which does pass a visual inspection is then connected to a test pump and the free end is fitted with a quick-opening valve. 9. Elevate the free end and fill the hose with water from the pump. Always use water. Never test with flammable or corrosive fluids, solvents or compressed gas. 10. As the hose fills with water, bleed the air out through the open valve. Close the valve and lower it to the ground when all the air is out. 11. RMA has testing literature available for each hose type. It is imperative to pressure test the hose at the proper pressure. 12. Drain the hose and allow it to dry before returning it to service. 1/7/2017 NAARSO 119
120 3. Inspect hose tube for hardness, color change, cracks, blisters, erosion, etc. 1/7/2017 NAARSO 120
121 Level 2 inspections should be conducted, if possible, during regular equipment shutdown or at least every three months even if it means shutting the equipment down for the specific purpose of hose inspection 1/7/2017 NAARSO 121
122 H O S E M A I N T E N A N C E T I P 1. Never exceed the rated working pressure of a hose. Never allow pressure spikes or surges above the maximum rated working pressure of the hose. Excessive pressure can shorten the life of a hose. 2. Never run over a hose with equipment or vehicles such as fork lifts. Running over a hose can damage the tube, reinforcement, and cover. A build up of pressure can cause damage at the coupling. 3. Never pull a hose by its coupling. Pulling a hose at the coupling can kink the hose and weaken the coupling bond to the hose. When moving a hose always lift the hose and coupling together. S 1/7/2017 NAARSO 122
123 4. Never lift a heavy, large-diameter hose by the middle with the ends hanging down. The internal reinforcement can be damaged at the middle point. Support large hose every ten feet with rope saddles or slings. Use dollies, rollers or derricks when moving large hoses. 5. Never over-bend a hose to the point of kinking. Never bend the hose tighter than the recommended bend radius. Never kink a hose to stop the flow of material. Kinking a hose can seriously damage the tube and reinforcement. If needed, install bend restricters at the coupling to prevent the hose from being bent past the bend radius. 6. A hose cover exposed to excessive wear can be protected with an extra cover, such as a nylon sleeve or pad. Make the cover slightly longer than the hose to accommodate any change in the hose length when in use. 7. Remove kinked or crushed hose from service immediately. Inspect and test the hose before putting it back in service. An outside diameter of a hose which has been permanently reduced by more than 20 percent should be removed from service. An outside diameter of a hose which has been reduced by 20 percent or less, should have a hydrostatic test done before being put back into service. See RMA 1/7/2017 NAARSO 123 Hydrostatic Testing Procedures
124 8. Remove and test any hose assembly that is subjected to abuse. This includes hose that has been severely pulled at the coupling, flattened, crushed or kinked. 9. Visually inspect and pressure test hose at regular intervals. This is extremely important for critical application hoses, such as acid/chemical, steam, LPG and petroleum. Check for kinks, bulges, soft spots, loose areas, abrasions and cuts. Cuts or abrasions which expose the reinforcement are signs that the hose should immediately be removed from service. 10. Always check for fluid seepage by pushing down at the base of the coupling with your thumbs. A hose softened by fluid seepage must be replaced. Check for coupling slippage. Remove any hose that does not pass your visual inspection. 1/7/2017 NAARSO 124
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HYDRAULIC / PNEUMATIC
HYDRAULIC / PNEUMATIC JOSEPH J. PANDOLFO N.A.A.R.S.O. 2012 joeboy@ptd.net 570-350-3359 1/31/2012 NAARSO 2 1/31/2012 NAARSO 3 BEFORE YOU DO ANYTHING ON OR WITH A PNEUMATIC/HYDRAULIC SYSTEM DO THE FOLLOWING!!!
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