ANCILLARY

HYDRAULIC
DEVICES
Supervised by:
Dr. Hamood Al-Nahari

Prepared by:
Amjad Hassan (202274070)
Mohammed Al-Mabrazi (202274007)
Riyadh Al-Kibsi (202274037)
ALPINE SKI HOUSE
Hashim Nabeel Al-Motwakel (202274093)
 INTRODUCTION

Ancillary hydraulic devices are those important components that do not fall
under the major categories of pumps, valves, actuators, conductors, and
fittings. This includes which include reservoirs, accumulators, pressure
intensifiers, sealing devices, heat exchangers, pressure gages, and flow
meters.

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 RESERVOIRS
 Design and Construction Features:

1- Hydraulic Reservoir:

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 RESERVOIRS
 Design and Construction Features:

2- Pneumatic Reservoir:

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 RESERVOIRS
 Sizing of Reservoirs:

1. It must make allowance for dirt and chips to settle

and for air to escape.

2. It must be able to hold all the oil that might drain

into the reservoir from the system.

3. 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.

4. It should have a surface area large enough to

dissipate most of the heat generated by the
system.

5. It should have adequate air space to allow for

thermal expansion of the oil.
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 Volume of tank= 3 to 5 times of the pump flow rate
 ACCUMULATORS
 Definition:

An accumulator is a device that stores potential energy by means of either gravity, mechanical springs, or
compressed gases. The stored potential energy in the accumulator is a quick secondary source of fluid power
capable of doing useful work as required by the system.

 Basic types of accumulators :

1-. Weight-loaded, or gravity, type.

2. Spring-loaded type.
3. Gas-loaded type.

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 ACCUMULATORS
1. Weight-loaded Accumulator:
• This type consists of 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. This type of accumulator creates
a constant fluid pressure throughout the full
volume output of the unit regardless of the
rate and quantity of output.
Graphic
• The main disadvantage of this type of Symbol
accumulator is its extremely large size and
heavy weight, which makes it unsuitable for
mobile equipment. ALPINE SKI HOUSE 7
 ACCUMULATORS
2. Spring-loaded Accumulator:
• The piston is preloaded with a
compressed spring. It is the source of
energy that acts against the piston,
forcing the fluid into the hydraulic
system to drive an actuator. 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.
Graphic
• This type of accumulator should not be Symbol
used for applications requiring high cycle
rates because the spring will fatigue,
resulting in an inoperative accumulator. ALPINE SKI HOUSE 8
 ACCUMULATORS
3. Gas-loaded Accumulator:
• The gas-loaded type is more practical
operates in accordance with Boyle’s law of
gases.

• 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.

• It Falls into two main Categories:

 Non-Separator type.
 Separator type.
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 ACCUMULATORS
 Non-Separator Type:

• There is no physical separator between the gas and oil, and thus the gas pushes directly on the oil.

• The main advantage of this type is its ability to handle large volumes of oil. The main disadvantage is absorption of the
gas in the oil due to the lack of a separator.

• This type must be installed vertically to keep the gas confined at the top of the shell, and is not recommended for use
with high-speed pumps because the entrapped gas in the oil could cause cavitation.

 Separator Type:

• In this type there is a physical barrier between the gas and the oil. This barrier effectively uses the
compressibility of the gas.
• Types of Separator accumulators:

1. Piston type.
2. Bladder type.
3. Diaphragm type. ALPINE SKI HOUSE 10
 ACCUMULATORS
 Piston Type:

 Disadvantages:  Advantages:
• expensive to manufacture. • ability to handle very high or low temperature
• have practical size limitations. system fluids through
• piston and seal friction problem in low-pressure ALPINE SKI HOUSE 11
systems
 ACCUMULATORS
 Bladder Type:

 Advantages:
• The primary advantage of this type of accumulator is its
small weight-to-volume ratio, which makes it suitable
almost exclusively for airborne applications. ALPINE SKI HOUSE 12
 ACCUMULATORS
 Diaphragm Type:

 Advantages:
• The primary advantage of this type of accumulator is its
small weight-to-volume ratio, which makes it suitable
almost exclusively for airborne applications. ALPINE SKI HOUSE 13
 ACCUMULATORS
 Applications:

1. An auxiliary power source :

The accumulator in this application is stores oil delivered by the pump during a portion of the work cycle. The accumulator
then releases this stored oil on demand to complete the cycle, thereby serving as a secondary power source to assist the
pump. This results in being able to use a smaller-sized pump.

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 ACCUMULATORS
2. A leakage compensator:

It is used as a compensator for internal or external leakage during an extended period of time during which the system is
pressurized but not in operation. For this application the pump charges the accumulator and system until the maximum
pressure setting on the pressure switch is obtained. The contacts on the pressure switch then open to automatically stop the
electric motor that drives the pump. The accumulator then supplies leakage oil to the system during a long period. Finally,
when system pressure drops to the minimum pressure setting of the pressure switch, it closes the electrical circuit of the
pump motor (not shown) until the system has been recharged. The use of an accumulator as a leakage compensator saves
electrical power and reduces heat in the system.

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 ACCUMULATORS
3. An emergency power source:

In some hydraulic systems, safety dictates that a cylinder be retracted even though the normal supply of oil pressure is lost
due to a pump or electrical power failure. Such an application requires the use of an accumulator as an emergency power
source.

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 ACCUMULATORS
4. A hydraulic shock absorber:

One of the most important industrial applications of accumulators is the elimination or reduction of high-pressure pulsations
or hydraulic shock. Hydraulic shock (or water hammer) is caused by the sudden stoppage or deceleration of a hydraulic fluid
flowing at relatively high velocity in a pipeline. The resulting rapid pressure pulsations or high-pressure surges may cause
damage to the hydraulic system components. If an accumulator is installed near the rapidly closing valve, the pressure
pulsations or high pressure surges are suppressed.

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 PRESSURE INTENSIFIER
 Introduction:
• A pressure intensifier is used to increase the
pressure in a hydraulic system to a value
above the pump discharge pressure. It
accepts a high-volume flow at relatively low
pump pressure and converts a portion of this
flow to high pressure.

• Applications such as the elimination of a high-

pressure/low-flow pump used in conjunction
with a low-pressure/high-flow pump

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 PRESSURE INTENSIFIER
 Pressure Intensifier Circuit:
• When the pressure in the cylinder reaches the sequence valve pressure setting, the intensifier starts to operate. The
high-pressure output of the intensifier closes the pilot check valve and pressurizes the blank end of the cylinder to
perform the punching operation.

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 PRESSURE INTENSIFIER
 Air-over-Oil Intensifier Circuit:
• The air-over-oil intensifier circuit uses shop air and hydraulic pressure to extend and retract a cylinder, providing low-
pressure and high-pressure oil to overcome loads, allowing for efficient operation.

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 SEALING DEVICES
 Introduction:

Hydraulic seals are a form of gasket-

like rings that are used to fill gaps
between hydraulic cylinder
components. Many different
components are found in hydraulic
cylinders, some of which get in
contact with the fluid. Hydraulic
seals are used to prevent fluid from
seeping around these components.
Hydraulic seals are made to suit the
components of a hydraulic cylinder
while providing a leak-proof seal.

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 SEALING DEVICES
 Considerations When Choosing a Seal:

• Shaft Speed: The maximum shaft speed is determined by the shaft finish, runout, housing bore and shaft
concentricity, kind of fluid being sealed, and oil seal material.

• Temperature Range: The temperature range of the mechanism in which the seal is installed must not be
higher than the seal elastomer's temperature range.

• Seals and Pressure: Most conventional oil seals are only intended to resist extremely low pressures (about 8
psi or less). If there is or will be increased internal pressure, pressure relief is required.

• Shaft Hardness: Shafts with a Rockwell (RC) hardness of 30 or higher might expect a longer seal life. The
hardness should be increased to RC 60 when subjected to abrasive pollution.

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 SEALING DEVICES
 Common Types of Seal:

1. O-rings:

O-rings are one of the most ubiquitous

types of hydraulic seals. They are circular
in shape and provide an effective seal
between two mating surfaces. O-rings
are typically made of elastomers such as
nitrile rubber, fluorocarbon (Viton), or
silicone and are known for their
versatility and cost-effectiveness.

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 SEALING DEVICES
 Common Types of Seal:

2. Piston Seals:

Piston seals are used in hydraulic

cylinders and provide a dynamic sealing
solution for reciprocating motion. They
are designed to withstand high pressure
and prevent fluid leakage around the
piston. Piston seals can be single-acting
(sealing in one direction) or double-
acting (sealing in both directions).

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 SEALING DEVICES
 Common Types of Seal:

3. Rod Seals:

Rod seals are similar to piston seals but

are used to seal the space between the
cylinder rod and the cylinder head. They
prevent fluid leakage and contamination
from entering the hydraulic system. Rod
seals can be single-acting or double-
acting, depending on the application
requirements.

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 SEALING DEVICES
 Common Types of Seal:

4. Wiper Seals:

Wiper seals, also known as scraper seals,

are used to clean contaminants, debris,
and moisture from the rod surface as it
retracts into the cylinder. They help
protect the rod seal and extend its life by
preventing external particles from
entering the system.

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 SEALING DEVICES
 Common Types of Seal:

5. U-cup Seals:

U-cup seals: U-cup seals, or U-seals, are

versatile sealing devices commonly used
in hydraulic applications. They have a U-
shaped profile and are designed to
provide effective sealing in both
directions. U-cup seals are typically made
of elastomers or thermoplastics.

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 SEALING DEVICES
 Common Types of Seal:

6. V-ring Seals:

V-ring seals: V-ring seals, also known as

axial face seals, are used for rotary shaft
applications. They consist of a flexible V-
shaped sealing lip that makes contact
with the shaft, providing effective sealing
against dust, dirt, and other
contaminants. V-ring seals can
accommodate shaft misalignment and
axial movement.

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 SEALING DEVICES
 Common Types of Seal:

6. Chevron Seals:

Chevron seals: Chevron seals, or chevron

packing, are used in dynamic applications
where high-pressure sealing is required.
They consist of multiple V-shaped rings
stacked together, forming a chevron
pattern. Chevron seals are suitable for
applications with reciprocating or
oscillating motion.

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 SEALING DEVICES
 Durometer Hardness Tester:

Is an instrument used to measure the

indentation hardness of rubber and
rubberlike materials. As shown, the
hardness scale has a range from 0 to
100.The durometer measures 100 when
pressed firmly on flat glass. High
durometer readings indicate a great
resistance to denting and thus a hard
material. A durometer hardness of 70 is
the most common value for seal materials

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 HEAT EXCHANGERS
 Introduction:
• A heat exchanger is a device which
transfers heat from one medium to
another.

• For example, Hydraulic Oil Cooler will

remove heat from hot oil by using cold
water or air.

• A heat exchanger is a system used to

transfer heat between two or more
fluids.

• Heat exchangers are used in both

cooling and heating processes. The fluids
may be separated by a solid wall to
prevent mixing or they may be in direct
contact. ALPINE SKI HOUSE 31
 HEAT EXCHANGERS

Advantages Disadvantages

High efficiency Large size

High operating pressure Double space needed for cleaning

Low pressure drop Difficult to clean shell side

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 HEAT EXCHANGERS
 Common Types Of heat Exchangers:

Air-cooled Heat Exchanger Shell & Tube Heat Exchanger

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 HEAT EXCHANGERS
 Fluid Temperature Rise Across Pressure Relief Valves:

The following equations permit the calculation of the fluid temperature rise as it flows
through a restriction such as a pressure relief valve:

 Sizing of Heat Exchangers:

When sizing heat exchangers in English units, a heat load value is calculated for the entire system in units of Btu/hr.
The calculation of the system heat load can be readily calculated by noting that 1 hp equals 2544 Btu/hr. Similar
calculations are made when sizing heat exchangers in metric units ALPINE SKI HOUSE 34
 PRESSURE GAUGE
 Introduction:

Pressure-measuring devices are needed in hydraulic circuits for a number of reasons. In addition to testing and
troubleshooting, they are used to adjust pressure settings of pressure control valves and to determine forces exerted by
hydraulic cylinders and torques delivered by hydraulic motors.

 Most Common Types of Pressure Gauges:

1- Bourdon Gage. 2-Schrader Gage.

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 FLOW METERS
 Introduction:

• Flow-rate measurements are frequently required to evaluate the performance of hydraulic components as well as to
troubleshoot a hydraulic system. They can be used to check the volumetric efficiency of pumps and also to determine
leakage paths within a hydraulic circuit.

• Flow-rate measurements are frequently required to:

 Evaluate the performance of hydraulic components.

 Troubleshoot a hydraulic system.

 They can be used to check the volumetric efficiency of pumps.

 Determine leakage paths within a hydraulic circuit.

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 FLOW METERS
 Types of Flow Meter:

1- Rotameter:

• Probably the most common type of

flowmeter is the rotameter, which consists
of a metering float in a calibrated vertical
tube.

• When no fluid is flowing, the float rests at

the bottom of the tapered tube, When
flow begins in the pipeline, the fluid
enters the bottom of the meter and raises
the float. This increases the flow area
between the float and tube until an
equilibrium position is reached.

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 FLOW METERS
 Types of Flow Meter:

2- Sight Flow Indicator:

• The sight flow indicator has two windows

located on opposite sides of the body
fittings to give the best possible visibility.
Such a device enables us to observe the
flow visually, it does not measure the rate
of flow but instead indicates only whether
or not there is flow or not.

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 FLOW METERS
 Types of Flow Meter:

3- Disk Piston:

• This Flow Meter incorporates a 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.

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 FLOW METERS
 Types of Flow Meter:

3- Disk Piston:

• This Flow Meter consists of 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. An electronic device connected to the
sensor converts the pulses to flow-rate
information.

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 FLOW METERS
 Electronic Digital Readout :

• a digital electronic readout device that

provides five-digit displays for flow-rate and
pressure and speed measurements accurate
to ±0.15% of full scale.

• The scale can be factory calibrated to display

values in units such as gpm, L/min, psi,
Pascals, bars, rpm, in/min, m/min, and so on.

• Data are updated two times per second and

provide an over-range condition indication.

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