Hydraulic and Pneumatic

Accessories

1
Reservoir

• Purpose of reservoir
• Storage element

• Location to settle water, sludge,

metal chips.

• Air picked by oil and allowed to

escape.

• Dissipation of heat

2
Reservoir: Baffle plate
• A baffle plate extends lengthwise across the
center of the tank. Its height is about 70% of
the height of the oil level.

• Purpose of Baffle plate

• Separate pump inlet from return line, so, prevent
same fluid from circulating.
• Permits foreign substances to settle to the bottom
• Allows entrained air to escape from oil
• Prevents localized turbulence in reservoir
• Promotes heat dissipation through reservoir walls

3
Size of Reservoir
• The average size of reservoir should be three times pump flow rate. This is based on
requirements like:
• It must make allowance for dirt and chips to settle and for air to escape.
• It must be able to hold all the oil that might drain into the reservoir from the system.
• It must maintain the oil level high enough to prevent a whirlpool effect at the pump inlet line
opening. Otherwise, air will be drawn into the pump.
• It should have a surface area large enough to dissipate most of the heat generated by the system.
• It should have adequate air space to allow for thermal expansion of the oil.

4
Accumulators

• Device for storing fluid potential energy by means of gravity, compressed air or
mechanical spring. The stored fluid act as secondary source of fluid power.

Accumulators

Weight Spring Gas

Separator Non-Separator

Piston Diaphragm Bladder

5
Accumulators: Weight loaded
• It is historically the oldest. A vertical, heavy-wall steel cylinder, which
incorporates a piston with packings to prevent leakage. A deadweight is
attached to the top of the piston.

• The force of gravity of the deadweight provides the potential energy in the
accumulator.

• Creates a constant fluid pressure throughout the full volume output of the
unit regardless of the rate and quantity of output.

• The main disadvantage of this type of accumulator is its extremely large size
and heavy weight, which makes it unsuitable for mobile equipment.

6
Accumulators: Spring loaded
• A spring-loaded accumulator is similar to the weight-loaded type except that
the piston is preloaded with a spring. The pressure generated by this type of
accumulator depends on the size and preloading of the spring.

• The pressure exerted on the fluid is not a constant. The spring-loaded

accumulator typically delivers a relatively small volume of oil at low pressures.
Thus, they tend to be heavy and large for high-pressure, large-volume
systems.

• This type of accumulator should not be used for applications requiring high
cycle rates because the spring will fatigue, resulting in an inoperative
accumulator.

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Accumulators: Gas loaded/ Hydro-pneumatic
• The compressibility of gases accounts for the storage of potential energy.

• Nitrogen is the gas used in accumulators because (unlike air) it contains no moisture. In addition, nitrogen is an
inert gas and thus will not support combustion.

Gas loaded

Separator
Non-Separator
There is physical barrier between gas and liquid.
No physical barrier.
The separators can be
Advantage: Able to handle large volume.
• Piston
Dis-advantage: Absorption of gas, so, non-
• Diaphragm
precise control and pump damage by cavitation
• Bladder
8
Gas-loaded: Piston separated accumulators
• Consists of a cylinder containing a freely floating piston with proper seals The piston serves
as the barrier between the gas and oil. A threaded lock ring provides a safety feature, which
prevents the operator from disassembling the unit while it is pre-charged.

• Disadvantages:
• Expensive to manufacture,
• Size limitations,
• Piston and seal friction may also be a problem in low-pressure systems,
• Appreciable leakage tends to occur over a long period, requiring frequent pre-charging.

• Advantage : able to handle very high or low temperature system fluids through the use of
compatible O-ring seals.

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Gas-loaded: Diaphragm separated accumulator
• Consists of a diaphragm, secured in the shell, which
serves as an elastic barrier between the oil and gas.
• A shutoff button, prevents the diaphragm from being
pressed into the opening during the pre-charge period.
• Screw plug allows control of the charge pressure and
charging of the accumulator.
• Advantage: small weight-to-volume ratio, which makes
it suitable almost exclusively for airborne applications.

10
Gas-loaded: Bladder separated accumulator
• Contains an elastic barrier (bladder) between the oil and gas.

• The poppet valve closes the inlet when the accumulator

bladder is fully expanded. This prevents the bladder from
being pressed into the opening.

• Advantage of this type of accumulator is the positive sealing

between the gas and oil chambers.

• The lightweight bladder provides quick response for pressure

regulating, pump pulsation, and shock-dampening
applications.

11
Applications of Accumulators

• An auxiliary power source: can use with smaller size pump.

• A leakage compensator: helps to save electrical power and reduce heat.

• An emergency power source: back up for power failure to pump.

• A hydraulic shock absorber: reduce suppress high pressure surges.

12
Pressure Intensifier/ Booster
• Used to increase pressure of hydraulic system above pump
discharge pressure.

• The force of the low-pressure oil moves the piston and

causes the small area of the piston rod to force the oil out at
intensified high pressure.

• Pressure increase is directly proportional to ratio of piston to

rod area, inversely proportional to volume output.

= =
13
Sealing devices
• Seal: a device used to prevent leakage and contamination in a • Mostly used seal configurations
hydraulic system.
• O-rings
• Static seal: a seal used to prevent leakage between non-moving
• Compression packings (V-
parts.
and U-shapes)
• Dynamic seal: a seal used to prevent leakage between moving
• Piston cup packings
parts.
• Piston rings
• External leakage: loss of fluid from the system which will cause
volumetric in-efficiency. • Wiper rings

• Internal leakage: caused by wearing out of dynamic seal and which

will cause power in-efficiency.

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Seal configurations: O-rings
• The O-ring is one of the most widely used seals for
hydraulic systems. It is a molded, synthetic rubber seal
that has a round cross section in its free state.

• These O-ring seals give effective sealing through a wide

range of pressures, temperatures, and movements with
the added advantages of sealing pressure in both
directions and providing low running friction on moving
parts.

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Seal configurations: O-rings
• Installed in an annular groove machined into one of the mating parts. When it is initially

installed, it is compressed at both its inside and outside diameters. When pressure is applied,

the O-ring is forced against a third surface to create a positive seal. The applied pressure also

forces the O-ring to push even harder against the surfaces in contact with its inside and

outside diameters. As a result, the O-ring is capable of sealing against high pressures.

• Not generally suited for sealing rotating shafts or where vibration is a Problem.

• At very high pressures, the O-ring may extrude into the clearance space between mating

parts, This extrusion is prevented by installing a backup ring, If the pressure is applied in

both directions, a backup ring must be installed on both sides of the O-ring.

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Seal configurations: Compression packings
• Can be V or U ring type.

• V-ring packings are compression-type seals that are used in virtually all types of
reciprocating motion applications.

• They are also readily suited to certain slow rotary applications such as valve V-ring
stems.

• Frequently installed in multiple quantities for more effective sealing.

• In many applications these packings are spring-loaded to control the correct

force as wear takes place. However, springs are not recommended for high-speed
or quick reverse motion on reciprocating applications. U-ring

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Seal configurations: Piston cup packings

• Piston cup packings are designed specifically for pistons

in reciprocating pumps and pneumatic and hydraulic
cylinders.

• They offer the best service life for this type of

application, require a minimum recess space and
minimum recess machining, and are simply and quickly
installed
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Seal configurations: Piston rings
• Universally used for cylinder pistons.

• Metallic piston rings are made of cast iron or steel and plated with zinc phosphate or

manganese phosphate to prevent rusting and corrosion. Nonmetallic piston rings made

out of tetrafluoroethylene (TFE). Their extremely low coefficient of friction (0.04)

permits them to be run completely dry and at the same time prevents scoring of the

cylinder walls.

• Piston rings offer substantially less opposition to motion than synthetic rubber seals. High

pressures handled by using several rings. They are ideal solution for applications using

lubrication oil is dangerous like in an oxygen compressor.

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Seal configurations: Wiper rings
• Designed to prevent foreign abrasive or corrosive
materials from entering a cylinder. They are not
designed to seal against pressure.

• The wiper ring is molded from a synthetic rubber,

which is stiff enough to wipe all dust or dirt from the
rod yet pliable enough to maintain a snug fit.

• The rings are easily installed with a snap fit into a

machined groove in the gland. This eliminates the
need for and expense of a separate retainer ring.

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Seal Materials

• Natural rubber is rarely used as a seal material because it swells and deteriorates with
time in the presence of oil. In contrast, synthetic rubber materials are compatible with
most oils. The most common types of materials used for seals are

• Leather, • Neoprene,
• Buna-n, • Tetrafluoroethylene,
• Silicone, • Viton, and metals

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 Seal Materials
1. Leather: This material is rugged and inexpensive. However, it tends to squeal when dry and cannot operate above
200°F, which is inadequate for many hydraulic systems. Leather does operate well at cold temperatures to about -
60°F.

2. Buna-N: This material is rugged and inexpensive and wears well. It has a rather wide operating temperature range (-
50°F to 230°F) during which it maintains its good sealing characteristics.

3. Silicone: This elastomer has an extremely wide temperature range (-90°Fto 450°F). Hence, it is widely used for
rotating shaft seals and static seals where a wide operating temperature is expected. Silicone is not used for
reciprocating seal applications because it has low tear resistance.

4. Neoprene: This material has a temperature range of -65°F to 250°F. It is unsuitable above 250°F because it has a
tendency to vulcanize.
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Seal Materials
5. Tetrafluoroethylene: This material is the most widely used plastic for seals of hydraulic systems. It is a tough,

chemically inert, waxy solid, which can be processed only by compacting and sintering. It has excellent resistance

to chemical breakdown up to temperatures of 700°F. It also has an extremely low coefficient of friction. One

major drawback is its tendency to flow under pressure, forming thin, feathery films. This tendency to flow can be

greatly reduced by the use of filler materials such as graphite, metal wires, glass fibers, and asbestos.

6. Viton: This material contains about 65% fluorine. It has become almost a standard material for elastomer-type

seals for use at elevated temperatures up to 500°F. Its minimum operating temperature is -20°F.

23
Heat Exchangers/ Coolers
• Most of heat in hydraulic system generated by pump, pressure relief valve, and flow control valve. Effects of
excessive temperature includes hastens oxidation of hydraulic oil and causes it to become too thin. So,
deterioration of seal and packings occur this accelerates the wear of closely fitting components.

• Heat exchanger act as heater when we need to heat the fluid to attain some degree of viscosity. This is in cooler
environment and is not usual. But mostly natural heat-generation rate is sufficient to this purpose.

• The main types of heat exchangers are water coolers and air coolers.

• In the water cooler shown water is circulated through the unit by flowing
around the tubes, which contain the hydraulic fluid. The design shown has
a tough ductile, red-brass shell; unique flanged, yellow brass baffles;
seamless nonferrous tubes; and cast-iron bonnets.
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Pressure Gages/ Measuring device
• Pressure gages are used in hydraulic system is for

• Testing and troubleshooting

• Adjusting pressure setting of pressure control

valves

• Determining force exerted by hydraulic

cylinders or torque delivered by hydraulic
motors

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Common Pressure measuring devices
• Bourdon gage: The Bourdon gage contains a
sealed tube formed in the shape of an arc.
When pressure is applied at the port opening,
the tube starts to straighten somewhat. This
activates a linkage-gear system, which moves
the pointer to indicate the pressure on the dial.

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Common Pressure measuring devices
• Schrader gage: pressure is applied to a spring-
loaded sleeve and piston. As the pressure moves
the sleeve, it actuates the indicating pointer
through mechanical linkages.

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Flow meters
• A device used to measure the speed of fluid flow.

• Flow rate measurements are used for evaluating performance of hydraulic components, troubleshoot hydraulic
system, check the volumetric efficiency of pumps and determining leakages.

• Flow measuring devices includes

• Rotameter

• Disk piston

• Turbine flow meter

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Flow measuring devices: Rotameter
• It is the most common flow rate.

• When there is no flow the bob is at the bottom.

When the flow increases it need a path to flow so it
pushes the bob upward.

• Since, the area is wider upward the bob moves until

equilibrium is reached.

• At the equilibrium point flow rate can be read from

calibrated scale.

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Flow measuring devices
• Disk piston: When the fluid passes through the measuring
chamber, the disk piston develops a rotary motion, which is
transmitted through gearing to a pointer on a dial.

• Turbine: A turbine rotor mounted in a housing connected in a pipeline

whose fluid flow rate is to be measured. The fluid causes the turbine to
rotate at a speed proportional to the flow rate. The rotation of the turbine
generates an electrical impulse every time a turbine blade passes a sensing
device.

30
Filters and Strainers
• Filters and strainers are devices for trapping contaminants.

• Strainer is a coarse filter in straight path. Strainers are constructed of a wire screen that contains
openings less than 100 mesh (0.0059”~150 µm). The screen is wrapped around a metal frame. Because
strainers have low-pressure drops, they are usually installed in the pump suction line to remove
contaminants large enough to damage the pump.

• A pressure gage is normally installed in the suction line between the pump and strainer to indicate the
condition of the strainer. A drop in pressure indicates that the strainer is becoming clogged. This can
starve the pump, resulting in cavitation and increased pump noise.

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Filters
• Filter is a device whose primary function is to retain (twisted path) , by some porous medium, insoluble
contaminants from a fluid. filters can remove particles as small as 1 µm.

• Particles as small as 1 µm can have a damping effect on hydraulic systems (especially servo systems) and can also
accelerate oil deterioration.

• Basic types of filtering methods

1. Mechanical: Resistant

2. Absorbent: Suck

3. Adsorbent: Accumulate or collect

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Types of Filters
1. Mechanical: contains a metal or cloth screen or a series of metal disks separated by thin spacers.
Mechanical-type filters are capable of removing only relatively coarse particles from the fluid.

2. Absorbent: These filters are porous and permeable materials such as paper, wood pulp, diatomaceous
earth, cloth, cellulose, and asbestos. Paper filters are normally impregnated with a resin to provide added
strength. In this type of filter, the particles are actually absorbed as the fluid permeates the material. As a
result, these filters are used for extremely small particle filtration

3. Adsorbent: Adsorption is a surface phenomenon and refers to the tendency of particles to cling to the
surface of the filter. Thus, the capacity of such a filter depends on the amount of surface area available.
Adsorbent materials used include activated clay and chemically treated paper. Charcoal and Fuller’s earth
should not be used because they remove some of the essential additives from the hydraulic fluid.

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Filter location
• Suction line: located between reservoir and pump. Low pressure drop, so avoids pump cavitation, filter removes
contamination from container.

• Pressure line: Located between pump and Pressure relief valve. Protects pressure relief valve rest of the
components but will be subjected to pressure surges.

• Return line: Located in the main return line the main advantage of this type of filter is there will not be pressure
drop. Also, removes dirt introduced by the system.

• Bypass and bleed off: Filters only part of a fluid. Deployed to minimize full filtration cost. Incase of bleed-off
filter part of the fluid bleeds to the tank through filter.

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Beta ratio
• Beta ratio(𝛽 ): measure of performance of the filter

• 𝛽 =

• 𝜂 = 1− 𝑥100%

• x- selected particle size for the given filter

• 𝜂 - removal efficiency

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Pneumatic Accessories: Air Filter
• Remove contaminants from air.

• Filter cartridge: made from sintered brass or bronze and other materials

(like cellulose). Remove contaminants in the range of 5-50microns.

• Can hold large amount of contamination on surface without suffering any

pressure loss because they have large ratio of air to filter media.
Symbol
• The deflector removes most of contaminants before they reach the filter

element.

• Drain used to drain accumulated water and solid particles. Manual Auto drain

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Pneumatic Accessories: Air Pressure Regulators
• The amount of pressure at the output regulated using
adjustable spring.

• If the outlet pressure is greater than the pressure

setting, the pressure rises the diaphragm so the excess
pressure relieved to the atmosphere through pressure
relief vent.

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Pneumatic Accessories: Quick exhaust valve
• If higher speed of piston return is
required we need such type of
valve which can exhaust to
atmosphere quickly.

38
Pneumatic Accessories: Air Lubricators
• Insures proper lubrication of internal moving parts. By inserting
drops of oil into the air stream.

• The inlet air pushes oil from the tank into drip tube through
siphon tube.

• Droplets of oil enters into air forming oil-air. This oil-air mix
should be converted into mist using mist generator (an orifice) for
adequate lubrication.

Usually Filter, Regulator and Lubricator units comes in FRL unit

that can perform all three tasks.

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Pneumatic Accessories
• Silencers/ Mufflers: Used to control the noise caused by
rapidly exhausting airstream into the atmosphere.

• Compressed air exhausts generate high-intensity sound

energy.

• Excessive exposure to these noises can cause loss of hearing

without noticeable pain or discomfort.

• Noise exposure also causes fatigue and lowers production.

This noise problem can be solved by installing a pneumatic
silencer at each pneumatic exhaust port.

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Pneumatic Accessories: Aftercoolers
• Aftercooler is a heat exchanger that has two functions.

1. Cool the hot air discharged from the compressor to a desirable level
(about 80 to 100°F) before it enters the receiver.

2. Removes most of the moisture from the air discharged from the
compressor by virtue of cooling the air to a lower temperature.

• Moist air from compressor flows into an internal tubes of a shell. The shell is
filled with a coolant that is flowing in opposite direction to the air. The shell
contains baffles to provide proper coolant velocity and turbulence for high
heat transfer rates.

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Pneumatic Accessories: Air Dryers
• Aftercoolers remove only about 85% of the moisture. Air dryers are installed
downstream of aftercoolers when we want remove more moisture.

• There are three basic types of air dryers:

• Chemical: moisture absorbed by pellets made of dryer agent materials

like dehydrated chalk or calcium chloride so converted into liquid.

• Adsorption: captures moisture using pores on beds made of materials

like activated alumina or silica gel.

• Refrigeration: by cooling further the moisture is converted into liquid.

More effective than chemical and adsorption types.

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