Hydraulics TBT

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Hydraulic Systems
Reference: SWBT, Basic, Hyd
Version: 4
Release Date: 30-Sep-2005
EDMS UID: 274756147
Produced: 29-Sep-2005 19:53:00
Owner: WS Training
Author: WS Training
Private Basic, density,

Interface, WCS,hydraulic,
WPC, CTS, SWBT,
TBT WBT, IT Modu les,
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Copyright © 2005 Schlumberger, Unpublished Work. All rights reserved.
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Hydraulic Systems
Reference: SWBT, Basic, Hyd
Version: 4
Release Date: 30-Sep-2005
EDMS UID: 274756147
Published: 29-Sep-2005 19:53:00
Owner: WS Training
Author: WS Training
Private Basic, density,

Interface, WCS,hydraulic,
WPC, CTS, SWBT,
TBT WBT, IT Modu les,
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Copyright © 2005 Sophia, Unpublished Work. All rights reserved.
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Hydraulic Systems / Legal Information
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Legal Information
This work contains the confidential and proprietary trade secrets of Schlumberger
and may not be copied or stored in an information retrieval system, transferred,
used, distributed, translated or retransmitted in any form or by any means,
electronic or mechanical, in whole or in part, without the express written
permission of the copyright owner.
Trademarks & service marks
"Schlumberger", the Schlumberger logotype, and other words or symbols used

WS Training\WS Training\SWBT, Basic, Hyd\4\Release Date:30-Sep-2005\EDMS UID: 274756147\Produced: 29-Sep-2005 19:53:00
to identify the products and services described herein are either trademarks,
trade names or service marks of Schlumberger and its licensors, or are the
property of their respective owners. These marks may not be copied, imitated
or used, in whole or in part, without the express prior written permission of
Schlumberger. In addition, covers, page headers, custom graphics, icons, and
other design elements may be service marks, trademarks, and/or trade dress
of Schlumberger, and may not be copied, imitated, or used, in whole or in part,
without the express prior written permission of Schlumberger.
A complete list of Schlumberger marks may be viewed at the Schlumberger

Oilfield Services Marks page: http://www.hub.slb.com/index.cfm?id=id32083
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1-i Hydraulic Systems / Objectives 1-i
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1 Objectives
WS Training\WS Training\SWBT, Basic, Hyd\3\Release Date:30-Aug-2003\EDMS UID: 274756116\Produced: 29-Sep-2005 19:53:00
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1-1 Hydraulic Systems / Objectives 1-1
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1 OBJECTIVES Basic, density, hydraulic
In this training module, you will learn to do the following:
• Identify the advantages of using hydraulic power.

• Become familiar with hydraulic systems symbology.
• Understand the various hydraulic components: pumps, actuators, pressure
valves and directional control valves.
• Understand the basic concepts of hydraulic systems maintenance.
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1-2 Hydraulic Systems / Objectives 1-2
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2-i Hydraulic Systems / Introduction to Hydraulic Systems 2-i
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2 Introduction to Hydraulic Systems
2.1 Hydraulic force animation ______________________________________ 2-1
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2-1 Hydraulic Systems / Introduction to Hydraulic Systems 2-1
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2 INTRODUCTION TO HYDRAULIC SYSTEMS Basic, density,

Interfac e, WCS,hyWPC,
draulic,
CTS,
SWBT,
TBTWBT, IT Modules,
Hydraulics, the study of the behavior of liquids, allows us to understand how

forces are created and how the tremendous potential of fluid power can be
effectively applied.
The word hydraulic comes from the Greek hydro, meaning water, and aulos,
meaning pipe.
Pascal’s law states that "Pressure applied on a confined fluid is transmitted

undiminished in all directions, and acts with equal force on equal areas, and at
right angles to them." Keeping Pascal’s law in mind, what would you expect to
happen if a piston was forced into a bottle that was completely filled to the rim
with water?
As shown here, the bottle would break because the liquid is practically
incompressible and transmits the force applied at the piston throughout the
container. This is a simple example of hydraulic forces.
2.1 Hydraulic force animation
Multimedia 2-1: Hydraulic force in a bottle. Animation

NOTE: Multimedia is currently available only in HTML publications.
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2-2 Hydraulic Systems / Introduction to Hydraulic Systems 2-2
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3-i Hydraulic Systems / Why Schlumberger Uses Hydraulic Power 3-i
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3 Why Schlumberger Uses Hydraulic Power
3.1 Why Schlumberger Uses Hydraulic Power ______________________ 3-2
3.2 Exercise ________________________________________________________ 3-2
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3-ii Hydraulic Systems / Why Schlumberger Uses Hydraulic Power 3-ii
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3-1 Hydraulic Systems / Why Schlumberger Uses Hydraulic Power 3-1
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3 WHY SCHLUMBERGER USES HYDRAULIC

POWER Basic, density,
draulic,
CTS,
SWBT,
TBTWBT, IT Modules,
Figure 3-1: Hydraulic hoses
Schlumberger uses hydraulic power for tasks such as mixing, proportioning

and agitating in cement mixers and liquid- and dry-additive systems. These are
auxiliary circuits or systems that support downhole operations.
Hydraulic power is used for these applications because it offers a number of

advantages:
• produces high power output with very small weight and size
• requires minimum day-to-day maintenance because the same hydraulic
fluid used to drive the system is also used to lubricate the parts inside the
hydraulic system
• is simple to operate
• can be operated at varying speeds
• is reversible
• can be stalled without damage when overloaded and will start up immediately
when the load is reduced
• can be hooked up in a variety of configurations wherever they are needed
to operate most efficiently.
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3-2 Hydraulic Systems / Why Schlumberger Uses Hydraulic Power 3-2
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3.1 Why Schlumberger Uses Hydraulic Power

Figure 3-2: POD blender skid
Hydraulic systems are significantly less efficient than direct-drive systems

because of internal friction that produces heat, and they are prone to internal
leaks. They require less day-to-day maintenance than direct-drive systems
but require a qualified technician for major repairs. However, if you examine
equipment such as a coiled tubing unit and consider spatial restrictions and the
power transfer requirements, hydraulic devices provide the best load distribution
and packaging available.
3.2 Exercise
Why Schlumberger Uses Hydraulic Power Exercise
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4-i Hydraulic Systems / Basic Physics of Hydraulics 4-i
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4 Basic Physics of Hydraulics
4.1 Mechanical Advantage _________________________________________ 4-1
4.2 Horsepower ____________________________________________________ 4-3
4.3 Exercise ________________________________________________________ 4-3
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4 BASIC PHYSICS OF HYDRAULICS Basic, density,

draulic,
CTS,
SWBT,
TBTWBT, IT Modules,
Here’s a brief look at the basic physics of hydraulics.
4.1 Mechanical Advantage

Figure 4-1: Pressure and area determine force
To determine the total force exerted on a surface, it is necessary to know the

pressure or force on a unit of area. This is usually expressed in pounds per
square inch or psi. Knowing the pressure and the area on which it is being
exerted, the total force can be determined. Multiplying pressure times the area
will render the total force (that is, F = P x A).
The pressure, force, and area relationships are sometimes illustrated as shown
to aid in remembering the components.
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Figure 4-2: Large and small piston
But don’t be misled into believing that you get something for nothing. A
fundamental law of physics states that energy can neither be created nor
destroyed. It is conserved.
For example, a simple hydraulic press with a small piston, 1 square inch in area,
and an input force of 10 pounds will develop a pressure of 10 pounds per square
inch (10 pounds x 1 square inch).
If the small piston is moved 10 inches, it will displace 10 cubic inches of liquid
(1 square inch x 10 inches). How high will the 10 cubic inches of liquid move
a larger piston that is 10 square inches in area and 100 pounds in weight on
the output side?
The 10 cubic inches of liquid will move a larger piston that is 10 square inches
in area and 100 pounds in weight on the output side only 1 inch (10 square
inches / 10 inches).
The smaller piston will transfer the same amount of energy to the larger piston
(input side: 10 pounds x 10 inches = 100 in. pounds; output side: 100 pounds
x 1 inch = 100 in. pounds).
The larger piston is moved by the liquid displaced by the small piston, making
the distance each piston moves inversely proportional to its area. What is gained
in force must be sacrificed in distance.
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4.2 Horsepower
Hydraulic power is parasitic in nature because it derives power from other
sources. Therefore, it is sometimes necessary to determine the horsepower
(hp), or the metric watt (W) or kilowatt (kW), required to drive a hydraulic system.
This is a measure of the energy input into the system by the electric motor or
truck diesel engine.
Horsepower is equivalent to 33,000 pounds lifted one foot in one minute. (One
watt is equal to 1 newton lifted one meter in one second.)
In a hydraulic system,
• Speed and distance are determined by the fluid flow rate (Q) in gallons per
minute (gpm) or liters per minute (L/min).
• Force is determined by pressure (P) in pounds per square inch (psi) or
newtons per square meter (bar).
• Hydraulic power can be calculated by multiplying the pressure times the
fluid rate:
4.3 Exercise
Basic Physics of Hydraulics Exercise
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5-i Hydraulic Systems / Hydraulic System Components and Symbols 5-i
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5 Hydraulic System Components and Symbols
5.1 Fluid ___________________________________________________________ 5-1
5.2 Plumbing or Lines ______________________________________________ 5-2
5.3 Pumps _________________________________________________________ 5-3
5.3.1 Positive Displacement Pumps ________________________________ 5-3
5.3.1.1 Piston pump animation ___________________________________ 5-4
5.3.1.2 Gear Pumps _____________________________________________ 5-5
5.3.1.3 Vane Pumps _____________________________________________ 5-6
5.3.1.4 Piston Pumps ____________________________________________ 5-7
5.3.2 Non-Positive Displacement Pumps ____________________________ 5-7
5.3.2.1 Non-positive displacement animation ______________________ 5-8
5.3.3 Cavitation ___________________________________________________ 5-8
5.3.3.1 Cavitation animation ______________________________________ 5-9
5.4 Actuators ______________________________________________________ 5-9

5.4.1 Ratings _____________________________________________________ 5-10
5.4.1.1 Maximum Pressure Limitations ___________________________ 5-10
5.4.1.2 Displacement ___________________________________________ 5-10
5.4.1.3 Speed __________________________________________________ 5-11
5.4.1.4 Torque __________________________________________________ 5-12
5.4.1.5 Summary of Effects ______________________________________ 5-12
5.4.2 Cylindrical or Linear Actuator ________________________________ 5-13
5.4.2.1 Cylindrical Actuator animation ____________________________ 5-13
5.4.3 Rotational Gear, Vane, and Piston Motors ____________________ 5-14
5.4.3.1 Rotational gears animation _______________________________ 5-14
5.5 Reservoir _____________________________________________________ 5-15
5.6 Heat Exchangers ______________________________________________ 5-17
5.7 Filtering _______________________________________________________ 5-19
5.7.1 Filtering ____________________________________________________ 5-19
5.8 Valves _________________________________________________________ 5-23
5.8.1 Pressure Control Valves _____________________________________ 5-24
5.8.1.1 Direct relief valve animation ______________________________ 5-26
5.8.1.2 Pilot-operated relief valve animation ______________________ 5-26
5.8.2 Directional Control Valves ___________________________________ 5-26
5.8.2.1 Check valve animation ___________________________________ 5-28
5.8.2.2 Spool valve animation ___________________________________ 5-28
5.8.2.3 Four-way valve __________________________________________ 5-29
5.9 Gauges _______________________________________________________ 5-29
5.10 Exercise _______________________________________________________ 5-29
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5-1 Hydraulic Systems / Hydraulic System Components and Symbols 5-1
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5 HYDRAULIC SYSTEM COMPONENTS AND

SYMBOLS Basic, density,
draulic,
CTS,
SWBT,
TBTWBT, IT Modules,
Figure 5-1: Hydraulic system components and symbols
Here’s a brief look at each of the possible major components in a hydraulic

system and the symbol normally used to represent that component.
5.1 Fluid
Hydraulic systems rely on a fluid that must fulfill many requirements. It must be
capable of transmitting power efficiently, which calls for an incompressible, low
viscosity fluid. Any liquid is essentially incompressible and will transmit power
instantaneously in a hydraulic system. The fluid should be capable of lubricating
parts and seal clearances because all hydraulic components internally lubricate.
It must be able to dissipate heat and provide temperature stability. The fluid also
must prevent rust, resist aeration, and be economical to use.
Figure 5-2: Flow direction symbol
Although fluids are not normally illustrated in simple schematic diagrams, the
direction of flow is indicated by this symbol.
The fluids that are used for most hydraulic applications include synthetic fluids,
water glycols, water in oil-inverted emulsions, and petroleum-base fluids.
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At Schlumberger, the hydraulic fluid of choice is SAE 10 weight oil or Norm 159
HV32 for low temperatures. If operational temperatures are higher than normal,
then oil with higher temperature and viscosity stability should be used.
The recommended International Standards Organization (ISO) viscosity grades

for most Schlumberger equipment are
• ISO VG 32 for arctic climates

• ISO VG 46 for general use (the current manufacturing standard)
• ISO VG 64 for high-temperature applications
Oil is used because it readily transmits power due to the fact that it is only
slightly compressible. At 1000 psi, oil will compress about one-half of one
percent, a negligible amount in most systems. Water would be a superior fluid

to oil because it compresses at 1/10th the pressure of oil, but water can cause
undesirable corrosion.
The most critical maintenance required to keep hydraulic systems operational

is adding and maintaining clean oil.
5.2 Plumbing or Lines

The plumbing or lines connect each of the components in the system.
Figure 5-3: Rigid line symbol. Low-pressure line such as the line that
connects the reservoir to the pump.
Figure 5-4: Flexible line symbol. Used for discharge and return lines.
There are three basic classifications of lines.
Figure 5-5: Working line. Carries the main stream of flow in the system.
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Figure 5-6: Drain line. Carries leakage oil back to the reservoir.
Figure 5-7: Pilot line. Carries fluid that is used to control the operation
of a valve or other component.
5.3 Pumps
Pumps convert mechanical energy from an engine or electric motor into hydraulic
energy (hydraulic horsepower) by pushing fluid into the system.
A circle is the basic symbol for rotating components such as a pump. Energy
triangles are placed in the symbol to show them as energy sources or receivers.
If the energy triangle points out, it indicates the pump is an energy source.
Figure 5-8: Unidirectional pump. One triangle within the circle indicates a unidirectional pump.
Figure 5-9: Reversible pump. Two triangles within the circle indicates a reversible pump
Pumps are categorized as either positive displacement pumps or non-positive

displacement pumps.
Displacement is the total volume of fluid moved in one revolution of a rotary

device or one cycle of a linear device. Depending on the size of the pump or
actuator, displacement can be measured in cubic inches or cubic centimeters.
5.3.1 Positive Displacement Pumps

Positive displacement pumps are devices whose pump output is constant,
regardless of pressure, with the exception of changes in efficiency. They are
the most commonly used pumps in industrial hydraulic systems. A positive
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displacement pump delivers a specific amount of fluid per stroke, revolution,
or cycle to the system. The outlet is positively sealed from the inlet, so that
whatever gets into the pump is forced out the outlet or discharge port.
The sole purpose of a pump is to create flow. Pressure is caused by resistance

to flow. Although there is a common tendency to blame the pump for a loss of
pressure, pressure can only be lost when there is a leakage path that will divert
all of the flow from the pump.
Positive displacement pumps are categorized into fixed displacement pumps and
variable displacement pumps. Fixed displacement pumps have a displacement
that cannot be changed without replacing certain components. Variable
displacement pumps can vary the size of the pumping chamber (and the
displacement) by using external controls.
Here are the three most common positive displacement pumps.
• gear pumps
• vane pumps
• piston pumps.
5.3.1.1 Piston pump animation
Multimedia 5-1: Piston in motion. Animation

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5.3.1.2 Gear Pumps

Figure 5-10: Gear pump fluid flow
A gear pump develops flow by carrying fluid between the teeth of two meshed
gears. Powered by the drive shaft, the gear known as the drive gear turns the
second gear, which is called the driven or idler gear.
Click on the animation below for a demonstration.
Gear pumps tend to be the least efficient pump type, retaining only 70% of input
power with the remaining 30% lost to heat and sound.
Gear pumps are easy to manufacture and, therefore, relatively inexpensive.

Gear pumps also are more tolerant of contaminants.
Gear pumps are positive displacement pumps.
Gear pump animation
Multimedia 5-2: Gear pump in motion. Animation

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5.3.1.3 Vane Pumps

Figure 5-11: Vane pump components
In vane pumps, a slotted rotor is splined to the drive shaft and turns inside a
cam ring. Vanes are fitted to the rotor slots and follow the inner surface of the
ring as the rotor turns.
Vane pumps are positive displacement pumps.
Most fixed displacement vane pumps use a balanced design in which the cam
ring is elliptical rather than circular. This elliptical design forms two sets of ports
(on opposite sides of the rotor) that are connected through passages within the
housing. Because the ports are positioned 180 degrees apart, forces caused by
pressure buildup on one side are canceled out by equal, but opposite, forces
on the other side. As a result, friction is reduced, which allows higher system
pressure capabilities.
Vane pumps operate at around 80% efficiency.
Vane pump animation
Multimedia 5-3: Vane pumps with fluid flow. Animation

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Change of flow direction animation
Multimedia 5-4: The position of Cam ring determines direction of flow. Animation
5.3.1.4 Piston Pumps

Piston pumps operate on the principle that a piston reciprocating in a bore will
draw fluid in as it is retracted and expel the fluid as it moves forward.
The two basic piston pump designs are radial and axial. Radial pumps have
pistons arranged in a cylinder block. Axial pumps have pistons parallel to each
other and to the axis of the cylinder block.
Both piston pump designs are available as fixed or variable displacement models.
Piston type devices offer the highest efficiency, operating at around 90%.
Piston pump animation
Multimedia 5-5: Piston reciprocating. Animation

5.3.2 Non-Positive Displacement Pumps

Non-positive displacement pumps or centrifugal pumps (C-pumps) are mainly
used for fluid transfer in systems where the only resistance is created by the
weight of the fluid and by friction.
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Most non-positive displacement pumps operate by centrifugal force. Fluids
entering the center of the pump housing are thrown to the outside by means of
a rapidly driven impeller. There is no positive seal between the inlet and outlet
ports, and pressure capabilities are a function of drive speed.
Although it provides a smooth, continuous flow, the output from this type of pump
is reduced as resistance is increased. In fact, it is possible to completely block
off the outlet while the pump is running. For this and other reasons, non-positive
displacement pumps are seldom used in power hydraulic systems today.
5.3.2.1 Non-positive displacement animation

Multimedia 5-6: Impeller in motion. Animation

5.3.3 Cavitation
Cavitation is second only to contamination in the hydraulic fluid as a source of
damage to hydraulic equipment.
Cavitation is often confused with entrained air (that is, air bubbles in the flow).
However, cavitation is caused when you pull suction on the fluid, and the
pressure at the pump drops below the vapor pressure of the fluid.
Below its vapor pressure, fluid in the intake line changes from a liquid to a
gaseous state. So if the hydraulic fluid is oil, the cavitation produces oil vapor.
Vapor pressure is the pressure at which a fluid boils at a given temperature.
When these oil vapor bubbles pass beyond the pump, the pressure immediately
increases and the oil vapor condenses to a liquid again. As these bubbles
collapse, there is a corresponding change in volume, and they produce a
characteristic sound, like gravel running through the pump. Collapsing cavitation
bubbles can cause localized stress that literally explodes out small fragments of
metal off the pump. This localized damage is called pitting damage.
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The best means of avoiding cavitation is by designing the equipment so there is
adequate net positive suction head (NPSH). One means of doing this is to place
the reservoir significantly higher than the pump, and also by always keeping
the reservoir full.
Net positive suction head is the hydrostatic equivalent of the pressure available
at the pump suction. NPSH must always be greater than the fluid’s vapor
pressure to prevent cavitation.
5.3.3.1 Cavitation animation

Multimedia 5-7: Cavitation bubbles in system. Animation

5.4 Actuators
Actuators convert hydraulic energy back into mechanical energy. The two types
of hydraulic actuators are cylinders and motors.
Figure 5-12: Cylinder or linear actuator. Represented by some version of this symbol.
Figure 5-13: Motor or rotary actuator. Represented by a circle and energy triangle(s).
Triangles point in to indicate that the motor receives energy.
Actuators can also be reversible, which is indicated by two inward pointing

triangles. Almost all the motors used by Schlumberger are bidirectional, or
reversible.
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5.4.1 Ratings
Here are some common characteristics of all motors. In particular, motors are
defined by their performance on four ratings:
• maximum pressure limitations

• displacement
• speed
• torque capacity.
5.4.1.1 Maximum Pressure Limitations

The pressure required is a function of the torque load and the displacement of
the hydraulic motor. Therefore, a motor with a large displacement can develop a
given torque with a lower pressure than a motor with a small displacement.
5.4.1.2 Displacement
Displacement is the total volume of fluid moved in one revolution of a rotary
device or one cycle of a linear device. Depending on the size of the pump or
actuator, displacement can be measured in cubic inches or cubic centimeters.
Here is an example of displacement: A 5-liter engine moves a total volume of 5

liters from all cylinders during each revolution of the crankshaft.
Flow Rate
A related issue to displacement is the flow rate of a motor. Flow rate can be
determined by multiplying the displacement by the rotations per minute of the
device.
Here is an example: A pump with a displacement of 5 cubic inches per rotation

operating at 2000 rpm will generate a flow rate of 10,000 cubic inches per minute
(displacement x rpm = flow rate).
To convert cubic inches into gallons, divide the total by 231 (i.e., there are 231
cubic inches in a gallon).
This division will give a flow rate in gallons per minute.
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10,000 cubic inches per minute / 231 cubic inches per gallon = 43.29 gallons per
minute.
Note
There are 42 gallons per barrel, so the above flow rate is approximately 1 barrel
per minute.
Volumetric Inefficiencies
Pumps and motors are not 100% efficient. Gear pumps and motors may operate
at 70%, vane pumps may operate at approximately 80%, and piston equipment
may operate at 90% efficiency.
If 43 gallons per minute flow rate is needed from the pump to move a motor at
2000 rpm, but the efficiency of the pump is only 70%, what flow rate is actually
needed from the pump?
43 gallons per minute / 0.7 (or 70%) = 61 gallons per minute flow rate needed.
If the motor is also operating at 70%, then what flow rate is needed?
61 gallons per minute / 0.7 (or 70%) = 87 gallons per minute.
As equipment wears out over time, the efficiency will degrade, and the
horsepower that must be input to generate the required output will have to
increase.
5.4.1.3 Speed
Motor speed is measured in revolutions per minute (rpm). For a hydraulic motor,
this is a function of the volume of fluid delivered to the motor and its displacement.
The maximum motor speed rating is the highest number of revolutions per
minute that the motor can maintain without sustaining damage at a given inlet
pressure over a specified period of time.
The minimum motor speed rating is the lowest revolutions per minute that allow
the motor to have a smooth, continuous rotation.
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5.4.1.4 Torque
Figure 5-14: Torque force
Torque is defined as a turning or twisting effort. It is the force component

of the output of a motor and is expressed in inch-pounds, foot-pounds or
Newton-meters.
Motor torque values are usually given for a specific pressure differential (or
pressure drop across the motor).
The mechanical efficiency of a motor is the ratio of its actual torque delivered to
its theoretical torque.
5.4.1.5 Summary of Effects

This table illustrates the relationship of the factors affecting motor performance.
This table assumes a constant load.
Table 5-1: Effects on motor operations
Change Speed Operating Pressure Available Torque

Increasing pressure 0 + +
Decreasing pressure 0 - -
Increasing flow rate
+ 0 0
(gpm)
Decreasing flow rate
- 0 0
(gpm)
Increasing
- - +
displacement
Decreasing
+ + -
displacement
0 = unaffected, + = increases, - = decreases
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5.4.2 Cylindrical or Linear Actuator

Figure 5-15: Cylindrical actuator
A cylindrical or linear actuator outputs straight-line motion and force. Perhaps

the simplest actuator is the ram type. It has only one fluid chamber and exerts
force in only one direction. Most are mounted vertically and retract by the force
of gravity on the load. Ram-type actuators are practical for long strokes and are
used in elevators, jacks and automobile hoists.
Figure 5-16: Ram-type actuator
5.4.2.1 Cylindrical Actuator animation
Multimedia 5-8: Straight-line motion and force. Animation

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5.4.3 Rotational Gear, Vane, and Piston Motors

Figure 5-17: Piston motors in coiled tubing unit
Rotational gear, vane, and piston actuators or motors are very similar in
construction and in operation to their respective pump types. Instead of pushing
on the fluid as the pump does, they are pushed by the fluid and develop torque
and a continuous rotating motion.
An example of a piston motor is the radial type used in coiled tubing units. These
motors run the chains in the injector head, which is the equipment that runs the
coiled tubing out of the hole.
5.4.3.1 Rotational gears animation
Multimedia 5-9: Fluid pushes gears

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5.5 Reservoir
Figure 5-18: Reservoir components
The reservoir stores the hydraulic fluid and feeds the pump suction. It allows the
oil to cool, dissipating heat from the oil. It also conditions the fluid by allowing
contaminants to settle and entrained air or air bubbles to escape.
The main functions of the reservoir are to
• hold the fluid

• dissipate heat
• allow entrained air to escape
• allow solids to settle.
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Figure 5-19: Reservoir symbols
A reservoir is represented by a rectangle with an open top if it is vented and with

a closed top if it is pressurized. For convenience, several symbols may be drawn
in a diagram even though there is only one reservoir in the system.
Connecting lines are drawn to the bottom of the symbol when the lines terminate
below the fluid level in the tank.
If a line terminates above the fluid level, the connecting line is drawn to the
top of the symbol.
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Figure 5-20: Atmospheric reservoir
The reservoirs used by Schlumberger are atmospheric and are fitted with a
vented breather to accommodate the air exchange due to constant change of
level within the tank. The reservoir walls are covered with resins to prevent
rusting due to moisture and temperature changes.
5.6 Heat Exchangers
Figure 5-21: Heat exchanger
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Heat exchangers are present on all hydraulic circuits to provide more efficient
temperature control of the hydraulic fluid than can be accomplished by the
reservoir alone, especially in severe conditions such as summer or desert
operations. Heat exchangers incorporate louvered airflow control and use either
electric or hydraulic fans to move air. They cool or heat fluid or air when water is
not readily available.
When jobs lasted 30 to 45 minutes, cooling the fluid wasn’t a significant issue, but
as jobs became more complex and lengthy, and pressures increased, filtration
had to be improved and coolers had to be retrofitted to Schlumberger equipment.
Figure 5-22: Heat exchanger symbols
Heaters are indicated by rectangles, turned to a 45-degree angle, with a line

drawn horizontally from corner to corner and an arrow drawn vertically, pointing
inwards.
Coolers are similar, but the arrows point outwards.
A cooler is a type of heat exchanger. An example is a radiator on an automobile

engine. To increase their efficiency, some coolers have either electrically or
hydraulically powered fans.
Placing a cooler in the flow of a hydraulic system faces the same constraints
as filters. In the pressure side, the cooler must be designed to operate in
high-pressure conditions and they are correspondingly expensive. As a result,
coolers are placed where they will have the least cost impact and are placed
after the filter. Typically, these constraints determine that coolers are placed
in the return line.
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5.7 Filtering
Figure 5-23: Filter
Contamination, which comes in the form of solids, liquids, or gases, can cause
major operational failures and intermittent problems, and degrade system
performance. Filtering is key to the good performance of a hydraulic system
because it removes contaminants that can damage the system.
5.7.1 Filtering
Contaminant sources include those:
• built in, such as debris left from the manufacturing process

• environmentally introduced, such as particles or moisture
• entering through a breather
• internally introduced, such as dirt in the fluid
Most of the damage to hydraulic systems occurs from either dirt or cavitation.
How does dirt get into our systems? When hot oil returns to the hydraulic
reservoir and cools, it contracts. It is not uncommon for the oil level to rise and
fall four to five inches in the reservoir. This change is called breathing.
Breathing cycles air in and out of the reservoir through the breathers. As water
vapor in the air condenses on the sides of the tank, the water runs down into
the oil and settles at the bottom of the tank. This water layer can cause rust and
emulsive sludges to build up.
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To prevent rusting, many tanks are now manufactured from stainless steel
or coated with special resins.
To prevent emulsive sludge or "milky" oil discoloration, daily draining of the

condensed water is required and should be performed prior to start-up while
cold. Additives may be placed in the oil to prevent sludge formation. However,
the best practice is to prohibit water "accumulation."
The majority of the dirt in a hydraulic system is put there unintentionally by the
operators.
As an example, a coiled tubing unit is compartmentalized and the hydraulic

system is connected using quick connects. Both ends of the quick connects
should be rinsed in diesel, blown off with an air hose, and then assembled. But
all too often the operators visually inspect the quick connects and simply wipe
off the connectors. (Visual inspection is only useful for particles down to 40
microns, but the particles that damage a hydraulic system are down in the 5 to
15 micron range.)
As another example, most hydraulic equipment leaks. On location, operators

add oil using any available container or by up-ending the drum and pouring oil
into the tank. The oil supplied from the manufacturer may have particle counts
up to 50,000 in the 5- to 15-micron range. However, the newer Schlumberger
equipment requires a particle count of only 50 to 100. Therefore, never pour
unfiltered oil into a Schlumberger unit.
Caution will prevent only a small percentage of contaminants, which is why

filtering is required. Small particles can disrupt critical clearances in the system
and can damage precise surfaces.
Contaminants can be kept to a minimum by
• ensuring that connectors are cleaned

• taking care when filling, flushing, or repairing the system
• draining the tank bottom daily.
Even with proper maintenance, wear still occurs in all hydraulic systems, and the
resulting small metal particles must be removed by a strainer or filter.
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Figure 5-24: Filter
To minimize choking the pump (low NPSH, low net positive suction head),
strainers are used to filter the suction. A red rag catcher (RRC), also called
a strainer, in the suction filters only larger particles out of the system using
100-mesh screens.
When oil is cold, even a strainer can provide enough restriction that oil won’t flow,
so strainers and filters have bypass systems. The bypass systems allow the free
flow of oil to minimize the loss in suction head (NPSH).
Strainers are coarse filters, normally installed on the suction line inside the
reservoir or tank. They are simple filtering elements constructed of fine mesh
wire screens. They could also be made of specially processed wire of varying
thickness wrapped around metal frames. Strainers do not provide as fine a
screening as filters. As a result, they allow full pump volume. Therefore, strainers
are less likely than filters to choke the pump.
Figure 5-25: Strainer and filter symbol
Filters are of medium porosity and are normally installed on the return line or
downstream of the pump. They are typically fine mesh with openings of about
10 microns.
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Strainers and filters are represented graphically by a rectangle turned at a
45-degree angle with a broken line drawn vertically from corner to corner.
Contamination is so damaging to hydraulic equipment that filters are installed for

contamination control in the:
• suction side
• pressure side
• return side.
A filter in the suction may choke the pump and cause cavitation.
A filter in the pressure side will help ensure that the fluid going to the motor
is clean. However, the differential pressure (delta P) of flow through the

filter requires expensive filters that are designed to operate in high-pressure
conditions.
A filter in the return still produces a differential pressure, but the maximum
pressure will be lower and a less expensive filter can be used. The low-pressure
filters will ensure that clean oil is returning to the reservoir. This process is called
post-filtration.
Most Schlumberger systems rely on both suction strainers and return

filters.
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5.8 Valves
Figure 5-26: Pressure and directional control valves
Valves in the hydraulic system serve many functions. They control the direction
of the hydraulic fluid, the maximum pressure in the system (for safety reasons),
the speed of the actuator, and the volume of fluid.
The main types of valves are
• directional control valves

• pressure control valves
• flow control valves.
Figure 5-27: Valve and flow path symbol
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The basic graphical symbol for a valve is a square, called an "envelope." Each
square in the directional control valve symbol represents a position of the
internal spool within the valve. In each position, different ports on the valve
are connected. Arrows are added to the envelopes to show flow paths and the
direction of flow.
Figure 5-28: Check valve and pressure control valve symbols
This is the symbol for a check valve, which is also used to control the direction of
flow.
This is the symbol for a pressure control or pressure relief valve.
5.8.1 Pressure Control Valves

Direct relief valves, or simple relief valves, are designed to limit pressure in the
system to a preset maximum by diverting some or all of the pump’s output to the
tank when the pressure setting is reached. They consist of a ball or poppet held
in the valve seat by a heavy spring. When pressure at the inlet is not enough to
overcome the force of the spring, the valve remains closed.
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Figure 5-29: Pressure relief valve components
When the preset pressure is reached, the ball or poppet is forced off the seat
and allows flow through the inlet to the reservoir for as long as pressure is
maintained. In most of these valves, an adjusting screw is provided to vary the
spring force to allow the valve to be set to open at any desired pressure.
Another type of relief valve, a style that is used on Schlumberger pump units, is
the pilot operated relief valve.
In normal operation, a balanced piston relief valve is in hydraulic balance.
Pressure at the inlet port, acting under the piston, is also sensed on its top by
means of an orifice drilled through to the upper chamber.
All hydraulic systems should include pressure control valves to keep the pressure
below the safe working pressure of all the components in the system. When the
set pressure is exceeded, the pressure relief valve will trip, allowing the pump
discharge to flow back to the reservoir.
Click on the animations below to view a demonstration.
At any pressure less than the valve setting, the piston is held in its seat by a light
spring. When pressure reaches the setting on the adjustable spring, the ball is
forced off its seat limiting pressure in the upper chamber.
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The restricted flow through the orifice into the upper chamber results in an
increase in the lower chamber. This unbalances the hydraulic forces and tends
to raise the piston off its seat.
When the difference in pressure between the upper and lower chambers is
sufficient to overcome the force of the light spring, the large piston unseats,
which permits direct flow to the tank.
5.8.1.1 Direct relief valve animation

Multimedia 5-10: Direct relief valve. Animation

5.8.1.2 Pilot-operated relief valve animation
Multimedia 5-11: Two stages of pilot operated relief-valve. Animatin

5.8.2 Directional Control Valves

Directional control valves start, stop, and control the direction of fluid flow.
Although they share this common function, they can vary considerably in
construction and operation.
A check valve is a one-way directional valve. Fluid flows freely in only one
direction, and it is blocked from flowing in the other direction.
In the free-flow direction, a poppet cracks open as pressure equals the spring
rating of the spring holding the ball or poppet seated in the flowline.
If pressure drops below the poppet spring rating, the spring seats the poppet
back in the flowline and seals off the flow.
Also, if flow is reversed down the line, the pressure adds to the poppet spring
tension and seats the poppet in the flowline, thus preventing flowback.
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Figure 5-30: Directional control valve
Spool valves are directional valves that direct flow from the inlet or pressure port
to either of two outlet ports. The number of ports to and from which fluid flows
determines whether it is a two-, three-, or four-way valve.
A two-way valve uses the pressure port and an outlet port in one shifted position
and the other outlet port in the other shifted position. The tank port is used only
as a drain for internal leakage flow.
When you change the position of the directional control valve, different parts
communicate, allowing the fluid to reverse direction.
A four-way valve selects alternate ports like the two-way valve, but the tank
port is used for return flow. A four-way valve can be used to move an actuator
in either direction.
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Figure 5-31: Needle valve
Flow control valves, in their simplest form, are nothing more than a variable
orifice and may be as basic as a needle valve. By varying the size of the opening,
the amount of oil entering the cylinder and thus its speed are regulated.
5.8.2.1 Check valve animation
Multimedia 5-12: Check valve in open and close position. Animation

5.8.2.2 Spool valve animation
Multimedia 5-13: Two-way valve. Animation

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5.8.2.3 Four-way valve
Multimedia 5-14: Four way valve in motion

5.9 Gauges
Figure 5-32: Pressure and temperature gauge symbols
Gauges are necessary to monitor pressure and temperature in the system.
Pressure gauges are represented by a circle with an arrow inside the circle.
Temperature gauges also use a circle, but with a thermometer symbol inside.
Schlumberger equipment is built so that the vent line runs to the control console
where it is tied into a pressure gauge with a relief valve. As an example, on a
c-pump, you can block off the pilot flow and watch the system pressure rise.
5.10 Exercise
Hydraulic System Components and Symbols Exercise
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6-i Hydraulic Systems / Theory of Hydraulic Circuitry 6-i
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6 Theory of Hydraulic Circuitry
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6-1 Hydraulic Systems / Theory of Hydraulic Circuitry 6-1
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6 THEORY OF HYDRAULIC CIRCUITRY Basic, density,

draulic,
CTS,
SWBT,
TBTWBT, IT Modules,
Figure 6-1: Hydraulic symbols
Hydraulics can now be defined as a means of transmitting power by pushing on

a confined fluid. The input component of the system is called the pump. The
output component is called an actuator.
In a simple system, hydraulic fluid is moved from a reservoir by the pump, which
pushes the liquid into lines. These lines then carry the liquid to actuators, which
are pushed to cause a mechanical output that moves a load. Drive speed can
be controlled by restricting the flow of the fluid through a valve. Drive direction
also can be changed by use of a directional valve. Pressure can be limited in
a hydraulic system by diverting the output of the pump with the use of a pilot
operated relief valve.
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6-2 Hydraulic Systems / Theory of Hydraulic Circuitry 6-2
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7-i Hydraulic Systems / Summary 7-i
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7 Summary
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7 SUMMARY Basic, density, hydraulic
This module has addressed
• why Schlumberger uses hydraulic power,

• basic physics of hydraulics,
• hydraulic system components and symbols, and
• theory of hydraulic circuitry.
This module should help you understand how forces are created and how the
tremendous potential of fluid power can be effectively applied.
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Private Basic, density,

Copyright © 2005 Schlumberger, Unpublished Work. All rights reserved.

Trademarks & service marks

"Schlumberger", the Schlumberger logotype, and other words or symbols used

A complete list of Schlumberger marks may be viewed at the Schlumberger

1 OBJECTIVES Basic, density, hydraulic

In this training module, you will learn to do the following:

• Identify the advantages of using hydraulic power.

2 INTRODUCTION TO HYDRAULIC SYSTEMS Basic, density,

Hydraulics, the study of the behavior of liquids, allows us to understand how

Pascal’s law states that "Pressure applied on a confined fluid is transmitted

2.1 Hydraulic force animation

Multimedia 2-1: Hydraulic force in a bottle. Animation

3 WHY SCHLUMBERGER USES HYDRAULIC

Figure 3-1: Hydraulic hoses

Schlumberger uses hydraulic power for tasks such as mixing, proportioning

Hydraulic power is used for these applications because it offers a number of

3.1 Why Schlumberger Uses Hydraulic Power

Figure 3-2: POD blender skid

Hydraulic systems are significantly less efficient than direct-drive systems

4 BASIC PHYSICS OF HYDRAULICS Basic, density,

Here’s a brief look at the basic physics of hydraulics.

4.1 Mechanical Advantage

Figure 4-1: Pressure and area determine force

To determine the total force exerted on a surface, it is necessary to know the

Figure 4-2: Large and small piston

5.4 Actuators ______________________________________________________ 5-9

5 HYDRAULIC SYSTEM COMPONENTS AND

Figure 5-1: Hydraulic system components and symbols

Here’s a brief look at each of the possible major components in a hydraulic

Figure 5-2: Flow direction symbol

The recommended International Standards Organization (ISO) viscosity grades

• ISO VG 32 for arctic climates

percent, a negligible amount in most systems. Water would be a superior fluid

The most critical maintenance required to keep hydraulic systems operational

5.2 Plumbing or Lines

There are three basic classifications of lines.

Pumps are categorized as either positive displacement pumps or non-positive

Displacement is the total volume of fluid moved in one revolution of a rotary

5.3.1 Positive Displacement Pumps

The sole purpose of a pump is to create flow. Pressure is caused by resistance

Here are the three most common positive displacement pumps.

5.3.1.1 Piston pump animation

Multimedia 5-1: Piston in motion. Animation

5.3.1.2 Gear Pumps

Figure 5-10: Gear pump fluid flow

Click on the animation below for a demonstration.

Gear pumps are easy to manufacture and, therefore, relatively inexpensive.

Gear pumps are positive displacement pumps.

Gear pump animation

Multimedia 5-2: Gear pump in motion. Animation

5.3.1.3 Vane Pumps

Figure 5-11: Vane pump components

Vane pumps are positive displacement pumps.

Click on the animation below for a demonstration.

Vane pumps operate at around 80% efficiency.

Click on the animation below for a demonstration.

Vane pump animation

Multimedia 5-3: Vane pumps with fluid flow. Animation

Change of flow direction animation

5.3.1.4 Piston Pumps

Piston pump animation