PRINCIPLES OF CONSTRUCTION AND

OPERATION OF HYDRAULIC
MACHINERY
• INTRODUCTION
• The most important material in a hydraulic system is
the working fluid
• Hydraulic fluid characteristics have a vital effect on
equipment performance and life.
• Clean and high-quality fluid is required in order to
achieve efficient hydraulic system operation.
 INTRODUCTION

• Definition: Hydraulics system can be defined

as power transmitting assemblies which use
pressurized fluid for transmitting energy from
source to energy using-point to achieve a task.
• Hydraulics is engineering science pertaining to
liquid pressure and flow. Hydraulics can be
divided into two areas namely, hydrostatic and
hydrodynamics.
 INTRODUCTION

• Hydraulic fluids are complex compound that

are carefully prepared to meet the task they
are designed for.
• Hydraulic fluids contain special additives to
provide desired characteristics.
• Hydraulics system generates forces and
motion using hydraulic fluids.
• Fluid is the medium for power transmission in
hydraulics system.
FUNCTIONS OF HYDRAULIC FLUIDS
• Hydraulic fluid is the transmitting medium of a hydraulic
system
• The most common liquid that is used as a medium in fluid
power systems is petroleum-based mineral oil.
In fluid power systems, a hydraulic fluid has to perform
some functions as follow
• 1. Power transmission: To transmit power, which is the
primary function.
• 2. Lubrication: To lubricate various parts, so as to avoid
metal-to-metal contact and
reduce friction, wear and heat generation.
FUNCTIONS OF HYDRAULIC FLUIDS
• 3. Sealing: To seal the moving elements to
avoid leakage.
• 4. Cooling: To carry away the heat generated
in the system and to dissipate the heat
through a reservoir or a heat exchanger.
• 5. Contaminant removal: To carry along the
contaminations to the tank, where they
can be removed through filters.
CHARACTERISTICS OF AN IDEAL HYDRAULIC
FLUID
•
1. Ideal viscosity.
2. Good lubrication capability.
3. Water resistance
4. Good chemical and environmental stability.
5. Incompressibility.
6. Fire resistance.
CHARACTERISTICS OF AN IDEAL HYDRAULIC
FLUID
• 7. Low flammability.
8. Foam resistance.
9. Low volatility.
10. Good heat dissipation.
11. Low density.
12. System compatibility
 TYPICAL APPLICATION FIELDS FOR HYDRAULICS SYSTEM

• Hydraulics has wide range of applications with

distinctions between stationary hydraulics and
mobile hydraulics.
• Mobile hydraulics move on wheels or tracks
while stationary hydraulics remains fixed in
one position
• Production and assembly machines of all type
• Transfer lines
 ILLUSTRATION OF HYDRAULIC SYSTEM
OPERATIONS

• Hydraulic System
 ILLUSTRATION OF HYDRAULIC SYSTEM
OPERATIONS

• Excavator
 ILLUSTRATION OF HYDRAULIC SYSTEM
OPERATIONS
• Hydraulic machinery is operated by the use of
hydraulics, where a liquid is the powering
medium
• Hydraulic machines are machinery and tools
that use liquid fluid power to do simple work.
Of which heavy equipment is a common
example
 ILLUSTRATION OF HYDRAULIC SYSTEM
OPERATIONS
• In the machine, hydraulic fluid is transmitted
throughout the machine to various hydraulic
motors and hydraulic cylinders and becomes
pressurized according to the resistance
present
• The fluid is controlled directly or automatically
by control valves and distributed through
hoses and tubes.
 ILLUSTRATION OF HYDRAULIC SYSTEM
OPERATIONS
Some Hydraulic Machine Parts
Hydraulic pump Hydraulic fluid

Actuators Filters

Reservoir Tubes, pipes and hoses

Accumulators Seals, fittings and connections

 APPLICATION FIELDS FOR
STATIONARY HYDRAULICS SYSTEM
• Lifting and conveying devices
• Presses
• Injection moulding machines
• Rolling lines
• Lifts
 APPLICATION FIELDS FOR STATIONARY
HYDRAULICS SYSTEM

• Figure 1. Lathe machine (Stationary hydraulics)

• In modern lathe machine operation, tools and work piece are clamped
by means of hydraulics
 APPLICATION FIELDS FOR STATIONARY HYDRAULICS SYSTEM

• Figure 2. Press with elevated reservoir (Stationary hydraulics)

 APPLICATION FIELDS FOR MOBILE HYDRAULICS SYSTEM

• Construction machinery
• Tippers, excavators, elevating platforms
• Lifting and conveying devices
• Agricultural machinery
 APPLICATION FIELDS FOR MOBILE HYDRAULICS
SYSTEM

• Figure 3. Mobile hydraulic system

• The working movement of the mobile hydraulics such as gripping,
lifting and are generated hydraulically. In addition, the drive mechanism
is also controlled by hydraulics
 APPLICATION FIELDS FOR MOBILE
HYDRAULICS SYSTEM
Hydraulics system in Aerospace equipment: There are
equipment and systems used for rudder control, landing gear,
breaks, flight control and transmission etc. which are used in
airplanes, rockets and spaceships
 HYDROSTATIC AND HYDRODYNAMICS
• Hydrostatics: Hydrostatics deals with the study of fluid at
rest. Applications include, hydraulic jack, hydraulic press
etc.
• Hydrodynamics: Hydrodynamic relates to the science of
moving liquids. Applications of hydrodynamics include
water wheel or turbine of which the energy used is created
by water motion.
 INTRODUCTION CONT’

• Figure 4. Hydro-mechanics system

 PRINCIPLES OF CONSTRUCTION OF
HYDRAULIC SYSTEM
Hydraulic principles are based on the following properties of
liquid,
• 1. Liquids conform to the shape of the container

• Figure 5. Three different shapes of containers connected

together
• As can be seen in figure1, the liquid confirms to the shape
of the containers
 PRINCIPLES OF CONSTRUCTION OF
HYDRAULIC SYSTEM
•2. Hydraulic fluids are incompressible

•Figure 6. Diagram showing that liquid is incompressible

•For hydraulic applications, hydraulic oil is considered ideal and
doesn’t compress at all.
•A liquid occupies the same amount of space or volume even when under
pressure. Gas is unsuitable for use in hydraulic systems because it
compresses.
 PRINCIPLES OF CONSTRUCTION OF
HYDRAULIC SYSTEM
• 3. Liquids transmit pressure equally in all directions

• Figure 7. Diagram showing the distribution of pressure in a pipe

• The pressure measured at any point in a hydraulic cylinder or line is the

same wherever.
• Most hydraulic systems use oil because it cannot be compressed and it
lubricates the system whereas, Water is unsuitable because,
1. it freezes at cold temperatures and boils at 100oC
2. it causes corrosion and rusting
PRINCIPLES OF CONSTRUCTION OF HYDRAULIC
SYSTEM

• Figure 8. Principle of hydraulic system

• Hydraulic machines are machinery and tools that use liquid
fluid power to do simple work, operated by the use of
hydraulics
PRINCIPLES OF CONSTRUCTION OF HYDRAULIC
SYSTEM

• Figure 9. Schematic of hydraulic system

PRINCIPLES OF CONSTRUCTION OF HYDRAULIC SYSTEM

The schematic of a simple hydraulic system is shown in

figure 6. It consists of:
• a movable piston connected to the output shaft in an
enclosed cylinder
• storage tank
• filter
• electric pump
• pressure regulator
• control valve
• leak proof closed loop piping.
 PRINCIPLES OF CONSTRUCTION OF HYDRAULIC
SYSTEM

• Figure 10. Hydraulic system

PRINCIPLES OF CONSTRUCTION OF HYDRAULIC
SYSTEM

• Where a container is constructed as shown in figure 8, it is

possible to transmit forces. The fluid pressure can be
described by means of the following equations

• The following equations applies if the system is in

equilibrium,
 Principles and Construction of Hydraulic
System Cont’

• Small forces from the pressure piston can produce larger

forces by enlarging the working piston surface. This is the
fundamental principle applied in every hydraulic system
from the jack to the lifting platform. The force must be
sufficient for fluid pressure to overcome the load
resistance.
PRINCIPLES OF CONSTRUCTION OF HYDRAULIC
SYSTEM
• Example:

• Figure 11. Lifting vehicle with hydraulic jack

PRINCIPLES OF CONSTRUCTION OF HYDRAULIC
SYSTEM
(1) A vehicle is to be lifted with hydraulic jack.
The mass m is 1500kg, A1 = 0.004m2 and A2 =
0.12m2, what force F2 is required at the piston
(1b) It has been observed that the force of
100N is too heavy for actuation by hand lever,
what must be the size of the piston surface
when only a piston force = 100N is available, F2
= 15000 and A1 = 0.004m2?
 HYDRAULIC PUMPS
Hydraulic pumps are used in hydraulic drive
system and can be hydrostatic or hydrodynamic.
It is a mechanical source of power that converts
mechanical power into hydraulic energy
Hydraulic Pumps:
– Hydraulic Pumps provide the flow needed to
transmit power from a prime mover to a hydraulic
actuator.
 HYDRAULIC PUMPS
– Types of Pumps
– Kinetic
‰ Axial Pump
‰ Centrifugal Pump
‰ Mixed Flow Pump
– Positive Displacement
‰ Reciprocating Piston or Plunger
‰ Gear Pump
‰ Screw Pump
‰ Lobe Pump
 HYDROPOWER SYSTEMS

• INTRODUCTION
• Hydroelectricity is the term referring to
electricity generated by hydropower; the
production of electrical power through the use
of gravitational force of falling or flowing water.
• Hydropower engineering tries to tap energy
available in the flowing water on the earth’s
surface and convert that to electricity.
 TURBINE – HYDROPOWER SYSTEM

• Hydraulic Turbine: Turbine is a hydraulic machine that

utilizes the energy of fluids to move other types of
machineries. A common use of turbine is in the hydroelectric
power generation plant.
• Turbines can be classified as: (a) Impulse turbine or Reaction
turbine
• Impulse turbine (Pelton wheel turbine) derives its energy from
a jet of water exiting out of a nozzle and shooting at the blades
of the turbine.
• (b) Reaction turbine (Francis or Kaplan turbine) derives its
power from the reactive power of fluid passing between its
blades.
 TURBINE – HYDROPOWER SYSTEM

• Hydraulic Turbines: Turbines generally convert hydraulic energy into

mechanical energy; the conversion of energy into usable mechanical
energy is completed by first converting the potential energy into
kinetic energy in the form of high-speed jets at the altitude of the
turbine wheel.
• For the energy conversion, one or many injectors are used. As second
step, the conversion of the kinetic energy of the jet into the
mechanical energy is accomplished by the interaction between the jet
and the rotating buckets of the Pelton turbine
Operation of selected Hydraulic Machinery
(Turbine – Hydropower system)

• Figure 12. Pelton Wheel Turbine

 HYDROPOWER SYSTEMS
• Hydropower is renewable resources and other
renewable resources include geothermal, wave
power, tidal power, wind power, and solar power
• Hydroelectric power plants do not use up resources
to create electricity or do they pollute the air, land,
or water like other power plants
• Hydroelectric power comes from flowing water when
it is falling by the force of gravity, can be used to turn
turbines and generators that produce electricity
 HYDROPOWER SYSTEMS
• Hydropower is an essential contributor in the national power
grid because of its ability to
respond quickly to rapidly varying loads or system disturbances,
which base load plants with steam systems powered by
combustion or nuclear processes cannot accommodate
• Hydroelectric plants do not create air pollution, the fuel (falling
water) is not consumed, the projects have long lives relative to
other forms of energy generation, and hydroelectric generators
respond quickly to changing system conditions. These favorable
characteristics continue to make hydroelectric projects
attractive sources of electric power.
 POWER GENERATION

• In nature, energy cannot be created or destroyed, but its

form can change.
• In generating electricity, no new energy is created but one
form of energy is converted to another form.
• To generate electricity, water must be in motion. This is
kinetic (moving) energy.
• When flowing water turns blades in a turbine, the form is
changed to mechanical energy.
• The turbine turns the generator rotor which then converts
this mechanical energy into another
energy form (electricity)
 POWER GENERATION

• Some power plants are located on rivers,

streams, and canals, but for a reliable water
supply, dams are needed.
• Dams store water for later release for such
purposes as irrigation, domestic and industrial
use, and power generation.
• The reservoir acts much like a battery, storing
water to be released as needed to generate
power
 POWER GENERATION

• Fig. A Power Generating System

 POWER GENERATION

• The dam creates a “head” or height from which

water flows. A pipe (penstock) carries the water
from the reservoir to the turbine.
• The fast-moving water pushes the turbine blades;
the waters force on the turbine blades turns the
rotor, the moving part of the electric generator.
• When coils of wire on the rotor sweep past the
generator stationary coil (stator), electricity is
produced.
 POWER TRANSMISSION

• Once the electricity is produced, it must be delivered to

where it is needed -- our homes, schools, offices,
factories, etc. Dams are often in remote locations and
power must be transmitted over some distance to its
users.
• Vast networks of transmission lines and facilities are
used to bring electricity to us in a form we
can use.
• All the electricity made at a power plant comes through
transformers which raise the voltage so it can travel long
distances through power lines.
 POWER TRANSMISSION

• Voltage is the pressure that forces an electric current

through a wire
• At local substations, transformers reduce the voltage so
electricity can be divided up and distributed throughout
an area.
• Transformers on poles (or buried underground, in some
neighborhoods) further reduce the electric power to the
right voltage for appliances and use in our homes.
• When electricity gets to our homes, we buy it by the
kilowatt-hour, and a meter measures how much we use.
 POWER TRANSMISSION

• Fig. Power Transmission System

 POWER TRANSMISSION

• While hydroelectric power plants are one source

of electricity, other sources include power plants
that burn fossil fuels or split atoms to create
steam which in turn is used to generate power.
• Gas turbine, solar, geothermal, and wind-
powered systems are other sources.
• All these power plants may use the same system
of transmission lines and stations in an area to
bring power to us.
 POWER TRANSMISSION

• Fig. Power Grid System

 POWER TRANSMISSION

• By use of this “power grid,” electricity can be

interchanged among several utility systems to meet
varying demands.
• Hence, the electricity lighting our home may be from a
hydroelectric power plant, a wind generator, a nuclear
facility, or a coal, gas, or oil-fired power plant or a
combination of these
• The area where you live and its energy resources are
prime factors in determining what kind of
power you use