Installation Testing Commissioning of Hyd Sys - Rev2.0 - Mar22

SPX FLOW’s PRODUCT TRAINING PROGRAM – LEVEL 1
POWER TEAM PRODUCT TRAINING COURSE
March 2022
POWER TEAM PRODUCTS TRAINING COURSE
CONTENTS
1. HYDRAULIC FUNDAMENTAL REVIEW
2. POWER TEAM CYLINDERS
3. POWER TEAM PUMPS
4. POWER TEAM HYDRAULIC ACCESSORIES
5. POWER TEAM SHOP EQUIPMENT
6. POWER TEAM HYDRAULIC JACKS
7. POWER TEAM HYDRAULIC & MECHANICAL TOOLS
8. POWER TEAM & POSI LOCK PULLERS
9. POWER TEAM & SPX HYDRAULIC TORQUE WRENCHES & TENSIONER
10. HYDRAULIC SAFETY & REGULATIONS
11. INSTALLATION - COMMISSIONING & TESTING HYDRAULIC SYSTEMS
INSTALLATION - COMMISIONING & TESTING HYD. SYSTEMS

OVERVIEW OF HYD. SYSTEM’S OPERATION
▪ Long service life and functional reliability of hydraulic systems and their
components depend on correct handling.
▪ Ensure trouble-free operation by observing the following points:
• The specific installation and operating instructions for the relevant components
• Special instructions in individual cases
• Technical data in the data sheet.
▪ Pay attention to the manufacturer’s regulations that were applied to products:
• ASME B30.1 standard
• German standard “Hydraulic systems“ DIN 24346
• ISO standard ISO 4413
INSTALLATION PROCEDURE
PREPARATORY WORK
▪ Ensure that the system is clean
• For the surroundings: Keep pumps, hoses/ fittings & components clean
or clean them
• For hydraulics fluids: Take care of contamination and humidity;
contamination from the environment must not enter the oil reservoir.
• For parts taken from stock: The storage of parts that were not filled or
treated with anti-corrosion fluid can lead to the formation of resin.
▪ Check to see that all of the parts required for the installation are available!
▪ Take note of any transport damage!
CARRYING OUT THE MONTAGE
▪ Use lifting lugs and transport facilities.
▪ Do not apply force to prevent transverse forces and tension on pipes and
components.
▪ When selecting pipes, hoses and fittings/flanges, observe the correct pressure
stage (wall thickness, material). Use only seamless precision steel pipes.
▪ Do not use hemp or putty as sealing materials! This may cause contamination
and thus malfunction.
▪ To prevent external leakage, observe the installation instructions of the pipe
fittings’ maker.
CARRYING OUT THE MONTAGE (Cont’d)
▪ Make sure that hoses are properly laid!
▪ Rubbing & abutting of the lines must be prevented.
▪ Provide the correct hydraulic fluids
▪ The following points must be observed in accordance with the relevant
requirements:
• Viscosity of the hydraulic fluid
• Operating temperature range
• Type of seals used on the components fitted
When the installation has been carried out correctly, proceed with
commissioning and functional testing.
TYPICAL SET-UP OF JACKING SYSTEMS WITH HAND PUMP
1. Single Acting Cylinders
2. Hydraulic Hand Pump
4. Pressure Gauge
5. Hydraulic Hose
8. Quick Couplers
10. Load-lowering Valves
11. T-Gauge Adapter.
TYPICAL SET-UP OF JACKING SYSTEMS WITH HAND PUMP
4. Pressure Gauge
5. Hydraulic Hose
8. Quick Couplers
9. Manifold & shut-off valves
12. Pipe Plug
TYPICAL SET-UP OF 4-POINT LIFTING
SYSTEMS WITH ELECTRIC PUMP
3. Directional Control Valve
4. Pressure Gauge
5. Hydraulic Hose
6. Manifold Block
7. Swivel Connectors
8. Quick Couplers
9. Manifold & shut-off valves
12. Pipe Plug
HYD. CIRCUITS OF 4-POINTS
SYNC LIFTING SYSTEM
1. Hydraulic Pump
2. Electric Control Box
3. PLC Controller
4. Pressure Gauge
5. Relief Valve
6. Flow Control Valve
7. Holding Valve
8. Manifold Block.
9. Sync Feeding Blocks
10. Pressure Transmitters
11. Needle Valve
13. Hydraulic Cylinders
14. Stroke Sensors
SET UP OF 4-POINT SYNC LIFTING SYSTEM
INSTALLATION OF JACKING SYSTEMS
Single-acting cylinder or cylinders in the circuit, Double-acting cylinder or cylinders in the circuit,
controlled by a pump-mounted valve. controlled by a pump-mounted valve.
NOTE: The diagrams are typical electric hydraulic units. Air or gas-driven pumps are available.
Single-acting cylinder controlled Double-acting cylinders controlled

by a remote-mounted valve. by a remote-mounted valve.
Single-acting cylinders with a sequence valve which Double-acting cylinder with a sequence valve which
controls the primary and secondary cylinder circuits. controls the primary and secondary cylinder circuits.
COMMISIONING & TESTING PROCEDURES

PREPARATIONS FOR TRIAL RUN
The followings need to be checked carefully before start-up:
▪ Tank cleaned?
▪ Lines cleaned and properly installed?
▪ Fittings, flanges tightened?
▪ Lines and components correctly connected in line with installation
drawings and circuit diagram?
▪ Are the drive motor and pump properly installed and aligned?
▪ Is the drive motor correctly connected?

PREPARATIONS FOR TRIAL RUN (Cont’d)
The followings need to be checked carefully before start-up:
▪ Are filters with the prescribed filter rating used?
▪ Are filters fitted in the correct direction of flow?
▪ Has the specified hydraulic fluid filled up to the upper marking?
As the hydraulic fluids often do not comply with the required

cleanliness, the fluids must be filled through a filter. The absolute
filter rating of the filling filter should be at least that of the filters
installed in the system.

TRIAL RUN
▪ For safety reasons, only personnel of the machine manufacturer and, if
required, maintenance and operating personnel should be present.
▪ All pressure relief valves, pressure reducing valves, pressure controllers of
pumps must be unloaded. An exemption to this are TÜV-set valves.
▪ Open isolator valves completely!
▪ Switch the system on briefly and check whether the direction of rotation of
the drive motor matches the prescribed direction of rotation of the pump.
▪ Check the position of the directional valves and, if necessary, move the
spool to the required position.

TRIAL RUN (Cont’d)
▪ Set the control spool to by-pass.
▪ Open suction valves of the pump. If required for design reasons, fill pump
housing with hydraulic fluids to prevent bearings and parts of the rotary
group from running dry.
▪ If a pilot oil pump is provided, commission it(1) .
▪ Start up the pump, swivel it from its zero position and listen for any noises.
▪ Swivel the pump slightly out (ca. 5°)(1) .
NOTE: (1) As far as possible with the control elements fitted; otherwise, start up at full displacement. In conjunction with
combustion engines, start up at idle speed.

▪ Bleed the system:
• Carefully loosen fittings or bleed screws at high points in the system.
• When the escaping fluid is free from bubbles → filling process is completed.
• Re-tighten fittings.
▪ Flush the system: If possible, short-circuit actuators.
• Flush the system until the filters remain clean; check the filters!
• During flushing, the hydraulic fluid in the complete hydraulic system should reach
temperatures that are at least as high as later during operation.
• Change the filter elements as required.
• Flushing continues until the required minimum cleanliness is reached.
• This can only be achieved by continuous monitoring using a particle counter.

▪ Check the system functions under no-load conditions, if possible, by
hand; cold-test the electrohydraulic control.
▪ When the operating temperature has been reached, test the system under
load; slowly increase the pressure.
▪ Monitor control and instrumentation equipment!
▪ Check the housing temperature of hydraulic pumps and hydraulic motors.
▪ Listen for noises!
▪ Check the hydraulic fluid level; if required, top up!

▪ Check the setting of pressure relief valves by loading or braking the system.
▪ Inspect the system for leaks.
▪ Switch off the drive.
▪ Retighten all fittings, even if there is no evidence of leakage (*).
▪ Is the pipe fixing adequate, even under changing pressure loads?
▪ Are the fixing points at the correct positions?
▪ Are the hoses laid so that they do not chamfer, even under pressure load?
▪ Check the fluid level.
(*) CAUTION! Only tighten fittings when the system is depressurized!

▪ Test the system for all functions: Compare measured values with the
permissible or specified data (pressure, velocity. Adjust further control components).
▪ Jerky movements indicate, amongst other things, the presence of air in
the system. By briefly swiveling the pump in one or both directions with the
actuator being loaded or braked, it is possible to eliminate certain air
pockets. The system is completely bled when all functions are performed
jerk-free and smoothly and the sur face of the hydraulic fluid level is free
from foam. Experience has shown that foaming should have ceased one
hour after start-up at the latest.

▪ Check the temperature.
▪ Switch off the drive.
▪ Remove filter elements (off-line and full-flow filters) and inspect them for residues.
Clean filter elements or replace them, if required. Paper or glass fibre
elements cannot be cleaned.
▪ If further contamination is found, additional flushing is required to prevent
premature failure of the system components.
▪ All the adjustments made are to be recorded in an acceptance report.

COMMISSIONING OF FAST RUNNING SYSTEMS
▪ Such system can often not be commissioning using the normal
measuring instruments (such as pressure gauges, thermometers, electrical multimeters, etc.)
and standard tools.
▪ Optimization is also not possible.
▪ Commissioning and optimization of these systems often require more
comprehensive measuring equipment to allow several measurements to
be taken at a time (e.g. several pressures, electrical signals, travel, velocities, flows, etc.).

THE MOST COMMON FAULTS OCCURRING DURING COMMISSIONING
Commissioning is very decisive for the service life & functional reliability of a
hydraulic system. For this reason, faults during commissioning must be avoided as
far as possible. The most common faults are:
▪ The fluid tank is not inspected.
▪ The hydraulic fluid is not filtered before being filled in.
▪ The installation is not checked before commissioning (subsequent conversion with loss of fluid!)
▪ System components are not bled.
▪ Pressure relief valves are set only slightly higher than the operating pressure
(closing pressure differential is not observed).

THE MOST COMMON FAULTS OCCURRING DURING COMMISSIONING (Cont’d)
▪ Pressure controllers of hydraulic pumps are set higher or to the same pressure
as the pressure relief valve.
▪ The flushing time of servo systems is not adhered to.
▪ Abnormal pump noise is ignored (cavitation, leaking suction lines, too much air in the hydraulic fluid).
▪ Transversal loads on cylinder piston rods are not observed (installation error!).
▪ Hydraulic cylinders are not bled (damage to seals!)
▪ Limit switches are set too low.

THE MOST COMMON FAULTS OCCURRING DURING COMMISSIONING (Cont’d)
▪ The switching hysteresis of pressure switches is not taken into account
when settings are made.
▪ Hydraulic pump and hydraulic motor housings are not filled with hydraulic
fluid prior to commissioning.
▪ Settings are not documented.
▪ Adjustment spindles are not secured or sealed.
▪ Unnecessary personnel present during commissioning of the system.
FUNCTIONAL TESTING OF HYD. COMPONENTS

HYDRAULIC TESTER / ANALYZER
1. In-line Flow meter

2. Flow Control Valve / Needle Valve
3. Pressure Gauge
4. Half Quick Coupler (Male or Female)

TESTING A PUMP
1. Connect the pump’s outlet to inlet of
hydraulic tester.
2. Ensure outlet of tester to flow to the pump’s
reservoir freely.
3. Fully open the flow control valve.
4. Turn on & operate the pump.
5. Carefully check the current through Multi-
Tester during functional testing at all time
(where applicable)
6. Gradually close flow control valve step by
step until full capacity of pump is reached.
7. Record the values of specified testing
pressure, flowrate, and current of electrical
motor (where applicable)

TESTING A RELIEF VALVE
1. Bypass the directional control valve at the point
of which relief valve still function well. The bypass
then is connected to the inlet of tester.
reservoir freely.
3. Fully open the relief valve & flow control valve.
5. Carefully check the current through Multi-Tester
during functional testing at all time (where applicable)
6. Fully close the flow control valve, then gradually
close relief valve step by step until the setting
pressure is achieved.
7. Record the values of specified testing pressure,
flowrate, and current of el. motor (where applicable)

TESTING A DIRECTIONAL VALVE
1. Bypass the hyd. cylinder at the points of which
directional valve still function well. The bypasses
(A/B) then is connected to the tester’s inlet.
reservoir freely.
5. Carefully check the current through Multi-Tester
during functional testing at all time (where applicable)
6. Operate the directional valve for all designed
functions while partially closing the flow control
valve until the max. working pressure is reached.
7. Record the values of specified testing pressure,
flowrate, and current of el. motor (where applicable)

TESTING A HYDRAULIC JACKS
SWL 200 TONNE
TESTING FRAME

TESTING A HYDRAULIC CYLINDER
Hydraulic Jack
1. Install the hydraulic jack into the right Testing Frame. Leakage Test
2. Connect the hydraulic tester to B port of hydraulic jack & B port
of directional valve as shown in the circuit here.
3. Switch on the pump & operate the directional valve in order to
extract the hydraulic jack against the external load.
4. Carefully check the current through Multi-Tester during functional
testing at all time (where applicable) Hydraulic
5. Build up system pressure until the testing pressure is reached. Tester
In case working pressure reduces due to oil leak, It is required to
build testing pressure up again to testing pressure.
6. Holding the testing pressure for a specified period of time (ie. A B
15 min / 30 min / 60 min / 12 hrs / 24 hrs…)
7. Record the values of specified testing pressure, flowrate of oil
leak, volume of leakage oil & current of el. motor (where applicable)
P T
INSTALLATION - COMMISIONING & TESTING HYD. SYSTEMS
THE END

Installation Testing Commissioning of Hyd Sys - Rev2.0 - Mar22

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Installation Testing Commissioning of Hyd Sys - Rev2.0 - Mar22

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SPX FLOW’s PRODUCT TRAINING PROGRAM – LEVEL 1

POWER TEAM PRODUCT TRAINING COURSE

INSTALLATION - COMMISIONING & TESTING HYD. SYSTEMS

Single-acting cylinder controlled Double-acting cylinders controlled

COMMISIONING & TESTING PROCEDURES

COMMISIONING & TESTING PROCEDURES

As the hydraulic fluids often do not comply with the required

COMMISIONING & TESTING PROCEDURES

COMMISIONING & TESTING PROCEDURES

COMMISIONING & TESTING PROCEDURES

COMMISIONING & TESTING PROCEDURES

COMMISIONING & TESTING PROCEDURES

COMMISIONING & TESTING PROCEDURES

COMMISIONING & TESTING PROCEDURES

COMMISIONING & TESTING PROCEDURES

COMMISIONING & TESTING PROCEDURES

COMMISIONING & TESTING PROCEDURES

COMMISIONING & TESTING PROCEDURES

FUNCTIONAL TESTING OF HYD. COMPONENTS

1. In-line Flow meter

FUNCTIONAL TESTING OF HYD. COMPONENTS

FUNCTIONAL TESTING OF HYD. COMPONENTS

FUNCTIONAL TESTING OF HYD. COMPONENTS

FUNCTIONAL TESTING OF HYD. COMPONENTS

FUNCTIONAL TESTING OF HYD. COMPONENTS

INSTALLATION - COMMISIONING & TESTING HYD. SYSTEMS

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