HYDRAULIC / PNEUMATIC

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2 HYDRAULIC / PNEUMATIC JOSEPH J. PANDOLFO N.A.A.R.S.O joeboy@ptd.net /31/2012 NAARSO 2

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4 BEFORE YOU DO ANYTHING ON OR WITH A PNEUMATIC/HYDRAULIC SYSTEM DO THE FOLLOWING!!! 1/31/2012 NAARSO 4

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6 LOCK OUT/TAG OUT DE ENERGIZE IT BLEED IT OFF KILL IT DEAD. OR IT WILL KILL YOU!!! 1/31/2012 NAARSO 6

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8 WHAT IS IT? 1/31/2012 NAARSO 8

9 NOT WHAT YOU THOUGHT. 1/31/2012 NAARSO 9

10 ANSI NFPA/JIC T ISO /31/2012 NAARSO 10

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14 Ahi A high pressure jet that h jttht sprays hydraulic oil constitutes a physical danger and an and environmental problem 1/31/2012 NAARSO 14

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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. 1/31/2012 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. 1/31/2012 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 1/31/2012 NAARSO 18

19 PRESSURE; FORCE PER UNIT AREA [POUNDS PER SQUARE INCH] 1/31/2012 NAARSO 19

20 Pressure Gage 1/31/2012 NAARSO 20

21 PRESSURE 1/31/2012 AND TEMPERATURE NAARSO 21

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23 The HYDRAULIC system 1/31/2012 NAARSO 23

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25 prime mover 1/31/2012 NAARSO 25

26 FLUID PUMP MECHANICAL ENERGY IS CONVERTED INTO FLUID ENERGY 1/31/2012 NAARSO 26

27 hd hydraulic (pressure) energy 1/31/2012 NAARSO 27

28 FLUID MOTORS FLUID ENERGY IS CONVERTED TO MECHANICAL WORK. 1/31/2012 NAARSO 28

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30 ACTUATORS DEVICE THAT CONVERTS FLUID ENERGY TO MECHANICAL 1/31/2012 NAARSO 30

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32 PARTS OF THE SYSTEM PUMP OIL RESERVOIR INTAKE FILTER PRESSURE GAGE RELIEF VALVE OUT PIPING 1/31/2012 NAARSO 32

33 HYDRAULIC SYSTEMS PUMPS 1.GEAR-TYPE 2.VANE-TYPE ROTARY PISTON-TYPE 4.RECIPROCATING PISTON 1/31/2012 NAARSO 33

34 HYDRAULIC FLUIDS 1.PETROLEUM-BASE FLUIDS 2.SYNTHETIC-BASE FLUIDS 3.WATER 1/31/2012 NAARSO 34

35 FUNCTION OF FLUID 1.TRANSMISSION OF FLUID POWER 2.MEANS OF LUBRICATION 3.ACTS AS SEALANT 1/31/2012 NAARSO 35

36 TYPES OF 1.PENNSYLVANIA/PARAFFIN-BASE OILS 2.GULF COAST/NAPHTHENIC&ASPHALTIC 3.MIDCONTINENT/MIXED MIDCONTINENT/MIXED-BASE OILS CONTAIN BOTH NAPHTHENIC &PARAFFIN 1/31/2012 NAARSO 36

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38 SYNTHETIC-BASE FIRE RESISTANT SLUDGE/GUM REDUCED LITTLE EFFECT ON TEMPERATURE 1/31/2012 NAARSO 38

39 DIRECTIONAL CONTROL O VALVES FUNCTION OF VALVE IS TO DIRECT OIL OR AIR TO A GIVEN PLACE IN A SYSTEM. 1/31/2012 NAARSO 39

40 TYPES OF VALVES TWO WAY TWO PORTS/TWO PASSAGES THREE WAY THREE PORTS/THREE PASSAGES FOUR WAY 4/4 1/31/2012 NAARSO 40

41 MANUAL CONTROL BY HAND OR FOOT/BODY PART MECHANICAL OPERATION CAM/ROTARY-SWING-TRIP PIN ELECTRICAL OPERATION MOTOR/SOLENOID 1/31/2012 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 1/31/2012 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 1/31/2012 NAARSO 43

44 MANUAL CONTROL BY HAND OR FOOT/BODY PART MECHANICAL OPERATION CAM/ROTARY-SWING-TRIP PIN ELECTRICAL OPERATION MOTOR/SOLENOID 1/31/2012 NAARSO 44

45 TYPES OF 1.METERING-IN 2.METERING-OUT 3.METERING BOTH DIRECTIONS 4.BLEED OFF 1/31/2012 NAARSO 45

46 ACCUMULATORS STORAGE DEVICE BATTERY CHEMICAL TO ELECTRICITY PIPE WITH CAP ACTS AS A CUSHION 1/31/2012 NAARSO 46

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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 1/31/2012 NAARSO 48

49 TYPES OF 1.WEIGHT-LOADED 2.SPRING-LOADED 3.AIR OR GAS NONSEPARATOR/SEPARATOR[DIAPHRAGM] 1/31/2012 NAARSO 49

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52 TYPES OF CYLINDERS; 1.SINGLE -ACTING 2.SPRING -RETURN 3.DOUBLE-END 4.TANDEM 5.DUPLEX TWO PISTONS/ROD INSIDE 1/31/2012 NAARSO 52

53 ROTATING & NONROTATING CYLINDERS 1/31/2012 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. 1/31/2012 NAARSO 54

55 Safety valve 1/31/2012 NAARSO 55

56 The PNEUMATIC system 1/31/2012 NAARSO 56

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58 AIR COMPRESSORS 1.POSITIVE-DISPLACEMENT/PRESSURE 2.VELOCITY/DYNAMIC 1/31/2012 NAARSO 58

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60 PARTS OF SYSTEM; AIR INTAKE AFTERCOOLER WATER SEPARATOR AIR RECEIVER AIR DISHARGE 1/31/2012 NAARSO 60

61 Air Receiver 1/31/2012 NAARSO 61

62 Aftercooler Filter, Regulator, Lubricator 1/31/2012 NAARSO 62

63 PNEUMATIC MOTOR 1.ROTARY 2.RECIPROCATING 1/31/2012 NAARSO 63

64 AIR FILTERS REMOVE ALL FOREIGN MATTER REGULATORS REDUCES OR REGULATES PRESSURE LUBRICATORS STORES OIL INJECTS OIL MIST OR FOG 1/31/2012 NAARSO 64

65 AIR FILTERS,REGULATORS, LUBRICATORS 1/31/2012 NAARSO 65

66 PIPING 1.RIGID 2.SEMI-RIGID/TUBING 3.FLEXIBLE/HOSE 1/31/2012 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. 1/31/2012 NAARSO 67

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72 Flared tube 1/31/2012 NAARSO 72

73 THE BAD GUYS DIRT HEAT MISAPPLICATION IMPROPER FLUIDS FAULTY INSTALLATION MAINTENANCE 1/31/2012 NAARSO 73

74 THE SAFE WAY IS THE ONLY WAY! 1/31/2012 NAARSO 74

75 A pressure vessel a closed, rigid container designed to hold gases or liquids at a pressure different from the ambient pressure. 1/31/2012 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 1/31/2012 NAARSO 76

77 Case Study Big Pneumatic Ride How about now? 1/31/2012 NAARSO 77

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79 Date of years old? 1/31/2012 NAARSO 79

80 VARIOUS TYPES OF CORROSION ATMOSPHERIC GALVANIC UNIFORM/GENERAL PITTING STRESS CORROSION CRACKING STRESS CORROSION CRACKING CREVICE CORROSION HIGH TEMPERATURE 1/31/2012 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. 1/31/2012 NAARSO 81

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87 Filter or Strainer 1/31/2012 NAARSO 87

88 Pneumatics: Symbols 1/31/2012 NAARSO 88

89 CAN YOU QUESS IT? 1/31/2012 NAARSO 89

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91 ONE MORE TRY 1/31/2012 NAARSO 91

92 FAT CHANCE.. 1/31/2012 NAARSO 92

93 HOSES AND THINGS

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96 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 en distribution tion 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. 1/31/2012 NAARSO 96

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98 PIPING FAILURES PRESSURE TOO HIGH. NOT PROPERLY SUPPORTED INCORRECTLY SIZED. TOO SMALL. HARDENING OF COPPER TUBING. 1/31/2012 NAARSO 98

99 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, id solids and mixtures ofthese materials. 2. As a flexible connector to absorb surges and vibrations. 3. As a conduit to protect other hose, pipes and wires. 1/31/2012 NAARSO 99

100 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 di on the 1/31/2012 NAARSO 100 application.

101 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). )Th The reinforcement if may consist of many layers of fabric, yarn or wire placed on top of the tube and referred to as plies. 1/31/2012 NAARSO 101

102 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. 1/31/2012 NAARSO 102

103 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. 1/31/2012 NAARSO 103

104 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. 1/31/2012 NAARSO 104

105 S - Size: I.D. (Inside Diameter) O.D. (Outside Diameter) Based on the machinery sizing. Flow rate requirements (GPM for liquids; id CFM for gases). 1/31/2012 NAARSO 105

106 T - Temperature: Consider exterior and interior temperature, as well as temperature impact on the material being conveyed. 1/31/2012 NAARSO 106

107 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 1/31/2012 NAARSO 107

108 M - Material Chemical name(s) and state(s) - (liquid, solid or gas) Food Dry or powder Liquid 1/31/2012 NAARSO 108

109 P - Pressure What is the working pressure? What is the maximum surge pressure? Is there a vacuum? 1/31/2012 NAARSO 109

110 E - End requirements What type of thread ends? Proper Coupling Selection? 1/31/2012 NAARSO 110

111 H O S E I N S P E C T I O N S Periodic Inspections Planning for Safety and Maximum Performance 1/31/2012 NAARSO 111

112 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 t are not properly maintained i can fail which h 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. 1/31/2012 NAARSO 112

113 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 1/31/2012 NAARSO 113

114 It is helpful lto think of hose inspection at two levels: 1/31/2012 NAARSO 114

115 Level 1 Inspection An inspection of hose on an on-going daily basis looking for signs such as: 1/31/2012 NAARSO 115

116 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. 1/31/2012 NAARSO 116

117 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 e that can degrade from contact with environmental factors. 1/31/2012 NAARSO 117

118 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. 1/31/2012 NAARSO 118

119 7. Damaged hose reinforcement. Weakened hose. 1/31/2012 NAARSO 119

120 Level 2 Inspection An inspection that requires equipment shutdown in order to conduct a more thorough evaluation of the hose in a safe manner. 1/31/2012 NAARSO 120

121 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, causingpainful 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. 1/31/2012 NAARSO 121

122 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 1/31/2012 NAARSO 122

123 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. 1/31/2012 NAARSO 123

124 3. Inspect hose tube for hardness, color change, cracks, blisters, erosion, etc. 1/31/2012 NAARSO 124

125 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 ofhose inspection i 1/31/2012 NAARSO 125

126 HOSE MAINTENANCE T IP S 1. Never exceed the rated working pressure of a hose. Never allow pressure spikes or surges above the maximum rated working pressure ofthe 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 a lift the hose and coupling together. 1/31/2012 NAARSO 126

127 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, d install bend restricters tit atth the coupling to prevent tth 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 hhas been reduced d by 20 percent or less, should have a hydrostatic test done before being put back into service. See RMA 1/31/2012 NAARSO 127 Hydrostatic Testing Procedures

128 8. Remove and test any hose assembly that is subjected to abuse. This includes ld hose that thth has been severely pulled lld atth the coupling, flattened, fltt 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. 1/31/2012 NAARSO 128

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HYDRAULIC / PNEUMATIC

HYDRAULIC / PNEUMATIC JOSEPH J. PANDOLFO N.A.A.R.S.O. 2017 joeboy@ptd.net 570-350-3359 1/7/2017 NAARSO 2 1/7/2017 NAARSO 3 BEFORE YOU DO ANYTHING ON OR WITH A PNEUMATIC/HYDRAULIC SYSTEM DO THE FOLLOWING!!!