CHAPTER-2

Hydraulic , Pneumatic and Electrical Telemetry Systems

 HYDRAULIC SYSTEM:-

The basic components of a fluid power system are essentially the same, regardless of whether the
system uses a hydraulic or a pneumatic medium. There are five basic components used in a
system. These basic components are as follows:
 Reservoir or receiver
 Pump or compressor
 Lines (pipe, tubing, or flexible hose)
 Directional control valve
 Actuating device
 Fundamentals of hydraulic pumps

A hydraulic pump is a mechanical device that converts mechanical power into hydraulic energy.
It generates flow with enough power to overcome pressure induced by the load.

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.

Reciprocating pumps

Figure. Reciprocating pump.

The positive-displacement principle is well illustrated in the reciprocating-type pump, the most
elementary positive-displacement pump, Figure 1. As the piston extends, the partial vacuum
created in the pump chamber draws liquid from the reservoir through the inlet check valve into
the chamber. The partial vacuum helps seat firmly the outlet check valve. The volume of liquid
drawn into the chamber is known because of the geometry of the pump case, in this example, a
cylinder.
As the piston retracts, the inlet check valve reseats, closing the valve, and the force of the piston
unseats the outlet check valve, forcing liquid out of the pump and into the system. The same
amount of liquid is forced out of the pump during each reciprocating cycle.
All positive-displacement pumps deliver the same volume of liquid each cycle (regardless of
whether they are reciprocating or rotating). It is a physical characteristic of the pump and does
not depend on driving speed. However, the faster a pump is driven, the more total volume of
liquid it will deliver.

Reservoir

The hydraulic fluid reservoir holds excess hydraulic fluid to accommodate volume changes from:
cylinder extension and contraction, temperature driven expansion and contraction, and leaks. The
reservoir is also designed to aid in separation of air from the fluid and also work as a heat
accumulator to cover losses in the system when peak power is used. Design engineers are always
pressured to reduce the size of hydraulic reservoirs, while equipment operators always appreciate
larger reservoirs. Reservoirs can also help separate dirt and other particulate from the oil, as the
particulate will generally settle to the bottom of the tank. Some designs include dynamic flow
channels on the fluid's return path that allow for a smaller reservoir.

Accumulators

Accumulators are a common part of hydraulic machinery. Their function is to store energy by
using pressurized gas. One type is a tube with a floating piston. On one side of the piston is a
charge of pressurized gas, and on the other side is the fluid. Bladders are used in other designs.
Reservoirs store a system's fluid.

Examples of accumulator uses are backup power for steering or brakes, or to act as a shock
absorber for the hydraulic circuit.

Hydraulic fluid

Also known as tractor fluid, hydraulic fluid is the life of the hydraulic circuit. It is usually
petroleum oil with various additives. Some hydraulic machines require fire resistant fluids,
depending on their applications. In some factories where food is prepared, either an edible oil or
water is used as a working fluid for health and safety reasons.

In addition to transferring energy, hydraulic fluid needs to lubricate components, suspend

contaminants and metal filings for transport to the filter, and to function well to several hundred
degrees Fahrenheit or Celsius.

Filters

Filters are an important part of hydraulic systems. Metal particles are continually produced by
mechanical components and need to be removed along with other contaminants.

Filters may be positioned in many locations. The filter may be located between the reservoir and
the pump intake. Blockage of the filter will cause cavitation and possibly failure of the pump.
Sometimes the filter is located between the pump and the control valves. This arrangement is
more expensive, since the filter housing is pressurized, but eliminates cavitation problems and
protects the control valve from pump failures. The third common filter location is just before the
return line enters the reservoir. This location is relatively insensitive to blockage and does not
require a pressurized housing, but contaminants that enter the reservoir from external sources are
not filtered until passing through the system at least once.filters are used from 7 micron to 15
micron depends upon the viscosity grade of hydraulic oil.

Tubes, pipes and hoses

Hydraulic tubes are seamless steel precision pipes, specially manufactured for hydraulics. The
tubes have standard sizes for different pressure ranges, with standard diameters up to 100 mm.
The tubes are supplied by manufacturers in lengths of 6 m, cleaned, oiled and plugged. The tubes
are interconnected by different types of flanges (especially for the larger sizes and pressures),
welding cones/nipples (with o-ring seal), several types of flare connection and by cut-rings. In
larger sizes, hydraulic pipes are used. Direct joining of tubes by welding is not acceptable since
the interior cannot be inspected.

Hydraulic pipe is used in case standard hydraulic tubes are not available. Generally these are
used for low pressure. They can be connected by threaded connections, but usually by welds.
Because of the larger diameters the pipe can usually be inspected internally after welding. Black
pipe is non-galvanized and suitable for welding.

Hydraulic hose is graded by pressure, temperature, and fluid compatibility. Hoses are used when
pipes or tubes can not be used, usually to provide flexibility for machine operation or
maintenance. The hose is built up with rubber and steel layers. A rubber interior is surrounded by
multiple layers of woven wire and rubber. The exterior is designed for abrasion resistance. The
bend radius of hydraulic hose is carefully designed into the machine, since hose failures can be
deadly, and violating the hose's minimum bend radius will cause failure. Hydraulic hoses
generally have steel fittings swaged on the ends. The weakest part of the high pressure hose is
the connection of the hose to the fitting. Another disadvantage of hoses is the shorter life of
rubber which requires periodic replacement, usually at five to seven year intervals.

Seals, fittings and connections

Components of a hydraulic system [sources (e.g. pumps), controls (e.g. valves) and actuators
(e.g. cylinders)] need connections that will contain and direct the hydraulic fluid without leaking
or losing the pressure that makes them work. In some cases, the components can be made to bolt
together with fluid paths built-in. In more cases, though, rigid tubing or flexible hoses are used to
direct the flow from one component to the next. Each component has entry and exit points for the
fluid involved (called ports) sized according to how much fluid is expected to pass through it.

There are a number of standardized methods in use to attach the hose or tube to the component.
Some are intended for ease of use and service, others are better for higher system pressures or
control of leakage. The most common method, in general, is to provide in each component a
female-threaded port, on each hose or tube a female-threaded captive nut, and use a separate
adapter fitting with matching male threads to connect the two. This is functional, economical to
manufacture, and easy to service.

A typical piece of machinery or heavy equipment may have thousands of sealed connection
points and several different types:
  Pipe fittings, the fitting is screwed in until tight, difficult to orient an angled fitting
correctly without over or under tightening.
 O-ring boss, the fitting is screwed into a boss and orientated as needed, an additional nut
tightens the fitting, washer and o-ring in place.
 Flare fittings, are metal to metal compression seals deformed with a cone nut and pressed
into a flare mating.

 PNEUMATIC SYSTEM:-

Important components of a pneumatic system are shown in fig.

a) Air filters: These are used to filter out the contaminants from the air.
b) Compressor: Compressed air is generated by using air compressors. Air compressors
are either diesel or electrically operated. Based on the requirement of compressed air,
suitable capacity compressors may be used.
c) Air cooler: During compression operation, air temperature increases. Therefore
coolers are used to reduce the temperature of the compressed air.
d) Dryer: The water vapor or moisture in the air is separated from the air by using a
dryer.
e) Control Valves: Control valves are used to regulate, control and monitor for control of
direction flow, pressure etc.
f) Air Actuator: Air cylinders and motors are used to obtain the required movements of
mechanical elements of pneumatic system.
g) Electric Motor: Transforms electrical energy into mechanical energy. It is used to
drive the compressor.
h) Receiver tank: The compressed air coming from the compressor is stored in the air
receiver.
PRINCIPLE
 Centrifugal pumps work on the principle of
forced vortex flow which means that when a certain mass of liquid is rotated in by an external
torque, rise in pressure head of rotating liquid takes place. Rise in pressure head is directly
proportional to the square of tangential velocity of the liquid at that point (pressure head directly
proportional to square of velocity ie, it is directly proportional to square of radius). Thus at outlet
of the impeller, where radius is more, the rise in pressure head will be more and the liquid will
be discharged at the outlet with a high pressure head. Due to this high pressure head, liquid will
be lifted to a high level.

PARTS OF A CENTRIFUGAL PUMP

Main parts of a centrifugal pump:
1. Impeller

It is the rotating part of the centrifugal pump. It consists of a series of backward curved vanes.
Impeller is connected to a shaft which is connected to an electric motor.
2. Vane
Vanes are backward curved blades connected to the impeller. It guides the water from the eye
of impeller to the casing.
3. Casing
It is an airtight passage surrounding the impeller. It is designed in such a way that water
discharged at outlet of the impeller is converted into pressure energy. From the impeller the
water moves to the delivery pipe.
 Important types of casings:

 Volute casing
It is a spiral type of casing in which area increases gradually. Increase in area decreases the
velocity of flow. The decrease in velocity increases the pressure of water flowing through the
casing.
The main disadvantage of volute casing is that, the efficiency of pump decreases as large
amount of energy is lost due to the formation of eddies in the casing.

 Vortex casing/whirlpool casings

In whirlpool casing, a circular chamber is introduced between the casing and impeller. This
circular chamber considerably reduces the formation of eddies and thus reduces the loss of
energy. Thus the efficiency of pump is increased.
4. Suction pipe
It is a pipe which is connected to inlet of pump whose other end is dipped into water in the
sump. At the bottom end a foot valve and a strainer is fitted. The foot valve is a non-return
valve, ie it allows water to flow only in upward direction, which automatically closes when water
flows backwards. The strainer prevents solid materials in water from entering the suction pipe.
5. Delivery pipe
Pipe whose one end is connected to outlet of pump and other end delivers water at a required
height. The delivery pipe collects the high pressure water coming out of the casing.

PRIMING AND CAVITATION

PRIMING
Priming is the operation in which the suction pipe, casing of the pump and a portion of the
delivery pipe is completely filled up from outside source with the liquid (usually water) to be
raised by the pump before starting the pump. Thus from these parts the air is removed and is
completely filled by the liquid.
Why priming is done?
When the pump is running in air, the head generated is much less compared to head generated
when the pump is filled with water. In such case, water may not be sucked from the pump. The
pump will be just rotating without rising the water to the required level. To avoid this priming is
done.

CAVITATION
Cavitation is the phenomenon of formation of vapour bubbles of flowing liquid in the region
where the pressure of the liquid falls below the vapour pressure, and the sudden collapsing of
the these vapour bubbles in a region of higher pressure. When the bubble collapse a high
pressure is generated. The metallic surface, above which these vapour bubbles collapse, is
subjected to high pressure and can cause pitting action on the surface. Thus cavities are formed
on the metallic surface and also considerable noise and vibrations are produced.