Basic Hydraulics

Content:
1. What & Why hydraulics
2. Metric in Hydraulics
3. Hydraulic Vs Pneumatics
4. Elements in hydraulics system with symbols & function
 Pumps
 Oil
 Pressure regulating valves
 Flow control valves
 Direction control valves
 Non return valves
 Counter balance valve
 Pipes & hoses
 Reservoirs
 Actuators
 Fittings
 Gauges
 .
 .
5. Instrumentation parts in hydraulics
 Pressure transmitters
 Flow meters
 RTD (Temperature sensors)
 Pressure switches
 Level sensors
 .
 .
6. Connection types
7. Selection of valves based on application
8. Valves flow calculation based on application
9. Overall hydraulic system design with simple circuits
What is Hydraulics?
Hydraulics is a system which is used to transmit the power by using oil from one place to
another place through pipes, hoses & other controlling elements (from hydraulic reservoir to
actuators such as cylinders & motors).

Why Hydraulics:
We can transmit the power through varies systems like electrical, mechanical, hydraulics
& pneumatics. But some of the following reasons we are selecting hydraulics.

 Lesser in size, compared to other transmissions. I.e. To lift the 10 ton of load with
speed of 100mm/s, we can use bore ɸ63mm hydraulic cylinder. If we decided go
with pneumatics, cylinder bore size will be ɸ1.5m due to pressure limitation & if it is
electrical 10kW motor (size 608mm x 430mm x 300mm) is required.
 High position accuracy & repeatability. We can stop the hydraulic cylinders within +/-
2 mm with full designed load & speed. In pneumatic cylinders, accuracy &
repeatability will be very less. If we want to match this accuracy we have to go with
servo electric cylinders which are costlier.

Metric in Hydraulics:
Measuring units using in hydraulics listed below.

Quantity Unit Symbol

Length Meter, Millimeter m, mm
Mass Kilogram kg
Time Second s
Electric Current Ampere mA
Electric Voltage Voltage V
Temperature degrees Fahrenheit, degrees Celsius, °K, °C
Pressure (above atmospheric) Bar, Pascal, PSI Bar, N/mm2, Pa, PSI
Pressure (below atmospheric) mm of Mercury mm of Hg
Flow Liters per minute l/min
Force Newton N
Mass kilogram kg
Volume (liquid) liters l
Torque Newton - meters Nm
Power watt W
Rotational Speed revolutions per minute RPM
Frequency hertz Hz
Displacement milliliters per revolution ml/rev
Kinematic Viscosity centistokes cSt
Velocity meters per second m/s

Hydraulics Vs Pneumatics:
Sl.
No. Hydraulic System
1 Oil or water is using to transmit power
2 It can be used in high power requirements
3 Suitable for jerk & impact loads
Ideally incompressible fluid (1% of volume
4 will get compress at 300bar)
Momentum can be controlled easily since
5 it is incompressible
High safety arrangements required since it
6 is high pressure
An oil hydraulic system operates at
7 pressures up to 700 bar
8 Generally designed as closed system
9 Maintenances are difficult
10 Heavier in weight
Pumps are used to provide pressurized
11 liquids
12 Food industries mostly not preferring
13 Lubrication system is not required
Pneumatic System
Mostly air is using to transmit power
It can be used in low power requirements
Not suitable for jerk & impact loads
Highly compressible fluid
Very poor momentum control
High safety arrangements not required
Pneumatic system usually operates at 7 bar
(100 psi)
Usually designed as open system
Maintenances are easy
Lighter in weight
Compressors are used to provide compressed
air
Suitable for food industries
Special arrangements for lubrication are
needed

Elements in hydraulic system:

Pumps:
A hydraulic pump is the device that converts mechanical energy into hydraulic energy,
which is a combination of pressure and flow.
Maximum Maximum
Type of Pressure Flow Application
Pumps
(bar) (l/min)

Centrifugal General purpose. Mostly used for water

20 3000s management
Used in higher viscous fluids like paint,
Gear ink, adhesives, butter, chocolate, sugar
175 300 etc.
Used in applications requiring medium
Vane operating pressures and low noise
175 500 emissions.
Axial Piston 300 500 Widely used in industrial hydraulics for
 actuators like presses & SPM
Multiple delivery ports will be there with
Radial
high pressure outlets. Used in injection
piston
700 650 molding machines, clamping cylinders

Unidirectional fixed & variable displacement pump.

Bi-directional fixed & variable displacement pump.

Centrifucal pump Gear pump Vane pump

Axial piston pump Radial piston pump

Oil:
Hydraulic medium is used to transmit the power in hydraulic system. Common hydraulic
fluids are based on mineral oil or water. Most of the hydraulic system is working at mineral oil.
Because of the following reasons we are not using water in the system.

 Compared to mineral oil water is having lesser viscosity (0.9cP), which leads to
more wear in the components & seals.
 Lesser freezing & boiling point.
  Corrosion – If we use water, we need to design the components with corrosion
resistance material which is more costlier than normal system.
 Water will not work as self lubricator, so we need to maintain separate
lubrication system for which are the components need lubrication.

Mineral oil is available with more number of grades based on their properties, mostly
differs with viscosity. Generally we are using ISO VG 46 & ISO VG 68 grade oil for power
transmission. Most of the hydraulic valves are designed to work at the preferred viscosity
range of 30cSt to 46cSt.
Oil properties:

Hydraulic oil ISO 46

Value in metric
Property unit
Density at 60°F (15.6°C) 871 kg/m³
Kinematic viscosity at 40°C 46 cSt
Kinematic viscosity at 50°C 30 cSt
Kinematic viscosity at 100°C 6.9 cSt
Flash point 220 ºC
Pour Point -30 ºC

Pressure regulating valves:

Hydraulic pressure regulators are used to maintain a specific set pressure in a system.
There are two types of pressure regulators available. (Pressure relief valve & Pressure reducing
valve)

Pressure relief valve:

 Manual pressure relief valve.

 Pilot operated pressure relief valve.

Pressure relief valves are mounted in parallel to the circuit & it will relieve the excess
pressure to tank with respect to our set pressure. These types of valves are used for
human & components safety.
Pressure reducing valve:

 Manual pressure reducing valve.

 Pilot operated pressure reducing valve.

Pressure reducing valves are mounted in series to the circuit & it will not allow the
excess pressure to the system with respect to our set pressure. These types of valves are used
to maintain constant pressure in a pipeline where the flow & pressure is fluctuating.

Flow control valves:

The purpose of a flow control valve is to regulate the flow rate in a specific portion of a
hydraulic circuit. In hydraulic systems, they're used to control the flow rate to motors and
cylinders, thereby regulating the speed of those components. There are four types in
hydraulics. 1) Dual side 2way flow control 2) Throttle with check valve, 3) Pressure
compensated flow control, 4) Flow dividers.

Dual side 2way flow control:

These type of flow control valves are used to control the flow in both direction (A-B & B-
A) by adjusting the knob which is mounted on top of the valve as shown picture. Also we can
choose fixed orifice type flow control valve without knob (non adjustable) if we know the
exact flow requirement.

Cross section Hydraulic symbol

Throttle with check valve:

Throttle with check valves are used for throttling the pilot and main flow of the
hydraulic fluid in the line A and B. These valves consist of two throttling spools with setting
screws and check valves which are built in housing. In direction V to P (see the hydraulic
symbol) flows the hydraulic fluid with low pressure loss through the check valve. In direction P
to V is the hydraulic fluid flow throttled depending on adjustment of the throttling spool.

Hydraulic symbol Example circuit

Pressure compensated flow control:

Pressure compensated three-way flow regulators are used to regulate the priority flow
in outlet 3 to a maximum adjustable level largely independent of the load and pressure
conditions. The surplus flow is diverted to the bypass port 2. The bypass flow may be used for
a secondary circuit. Whether the pressure in secondary circuit is higher than the regulated
pressure the valve works as two-way regulator.

Hydraulic symbol
Flow dividers:

The flow divider has two functions, dividing and combining of fluid flow. The regulator
divides the fluid flow in the direction from A to B and C, and combines flows in the direction
from B and C to A. The dividing / combining ratio is 50 % : 50 %, independent of pressure in
respective pipeline B or C.

Cross section Hydraulic symbol

Direction control valves:

Direction control valves are used to stop or allow or change the direction of the fluid.

Types of DC valves:
Based on port & position

 2/2 (2Ports & 2position)

 4/2 (4Ports & 2position)
 4/3 (4Ports & 3position)
o All ports blocked
o P connected to A & B; T blocked
o A & B connected to T; P blocked

where, P - Pressure line

T - Tank line
A - Connected to cylinder piston end port
B - Connected to cylinder rod end port
2/2 (2Ports & 2position):

2/2 DC valves are used to operate the single acting cylinders, on/off functions,
pilot operation functions, & etc...

4/2 (4Ports & 2position):

4/2 DC valves are used to operate the double acting cylinders, hydraulic motors &
etc…

4/3 (4Ports & 3position):

4/3 Valves are used to operate the double acting cylinders hydraulic motors as such as
4/2 valves. In addition to that, these valves having one more operating position which will use
the cylinder to switch their home position when the pilot failure occurred.

All ports blocked A & B connected to T; P blocked P connected to A & B; T blocked

Based on Pilot control:

Manual control Electric control Fluid control Mechanical control Electro-Hydraulic

Non-return valve or check valve:

A non-return valve allows a medium to flow in only one direction. A non-return valve is
fitted to ensure that a medium flows through a pipe in the right direction, where pressure
conditions may otherwise cause reversed flow. There are three types of check valves. 1. Direct
operated check valve, 2. Pilot operated check valve, 3. Counter balance valve.

Direct operated check valve:

Check valves permit the hydraulic fluid flow in one direction, with a tight-off in the
opposite direction. These valves consist of housing, poppet, and a spring. A poppet valve can
be fitted into the line P, T, A or B. This is made possible by the poppet which provides positive
seating. The hydraulic fluid flow under cracking pressure with variable value causes the poppet
to lift, thus freeing the flow. We can choose variable cracking pressure depending upon our
application. Hydraulic symbol

Pilot operated check valve:

Pilot operated check valves enable the hydraulic fluid flow in the service lines to be
automatically shut-off and made free, respectively.

Free flow direction is from the valve port B to port A. In the opposite direction is blocked
for the hydraulic fluid flow. Free flow from port A to port B is achieved by means of pressure in
port Z. Hydraulic symbol Example circuit
Counter balance valve:

Counterbalance valves are used with cylinders to safely hold suspended loads and deal
with over-running loads. This valve can also be used with hydraulic motors and is then
commonly called a brake valve. Both counterbalance valves and pilot-operated check valves
can be used to lock fluid in a cylinder to prevent drifting. However, a pilot-operated check
valve cannot control an over-running load. Whenever uncontrolled movement can occur from
an overrunning load, a counterbalance valve should be used.

Referring to above circuit, when no pressure is applied to the cap end of a cylinder, the
counterbalance valve maintains fluid pressure in the rod-end volume. The two pilot lines
shown act on different surface areas inside the counterbalance valve. The ratio of these areas
is usually 3:1 or 4:1. We’ll assume the 3:1 ratio. The line connected between the
counterbalance valve and cylinder’s rod-end port acts on a small piston area (1 in.2) inside the
valve. To overcome a spring force of 1,800 lb, the pressure would have to build to 1,800 psi.

Because the load in our example exerts a force producing only 1,500 psi, the valve remains
closed. To lower the load, the cap-end volume of the cylinder must be pressurized. The
external pilot line will then be pressurized to open the counterbalance valve. This is because
the external pilot line acts on a surface area three times (3 in.2) that which the internal pilot
pressure acts on.

Actually, 1,500 lb of force is already being exerted by the load on the spring. Therefore,
the external pilot pressure only has to develop 300 lb of additional force to open the valve.
Pressure only has to build to 100 psi on the 3 in.2 surface to develop the necessary 300 lb. of
force (Fig. 1).

The pressure and the weight of the load will cause the valve to open, allowing the load to
lower. The load dropping too fast would cause a pressure drop in the external pilot line. The
counterbalance valve’s spool would then partially close, preventing an uncontrolled drop of
the load

Fig – 1

Tubes & hoses:

Based on working pressure there are three types of pipe lines in hydraulic system such
as pressure line, return line & suction line.

Tubes:

Tubes are available in various sizes & thickness in the market. Commonly we are using the
tube with OD of 6mm, 8mm, 10mm, 12mm, 16mm, 20mm, 25mm, 38mm & 42mm.

Tube pressure:

We can select the thickness based on our application pressure rating by following formula.

Where,
  P - Working pressure
 K - Material characteristic value 226 N/mm2 (for material E235N (St. 37.4))
 s - Wall thickness
 c - Wall thickness divergence 0.9
 S - Safety correction value 1.5
 da - Pipe diameter

Example calculation:

Tube diameter “da” – 25mm, wall thickness “s” – 2.5mm,

P = (20*226*2.5*0.9)/(1.5*(25+2.5*0.9)) = 249 bar

Hence this tube can work up to 249bar pressure.

Tube diameter:

We can select the pipe diameter based on our required flow rate by following formula.

Parker recommended maximum velocity in tubes,

 Pressure lines - 7.5 m/sec

 Return lines - 3 m/sec
 Suction lines - 1.2 m/sec

Example calculation:

We want to select the tube for pressure line which has to handle the flow rate 130 lpm &
pressure 200 bar.

Since it is pressure line Vm - 7.5 m/sec, Qm – 130 lpm

dm = 4.61*(130/7.5)0.5 = 19.2mm

Hence our required tube ID will be 19.2mm, so we can select 25mm OD tube with 2.5mm
thickness.
Hoses:
The basic hydraulic hose construction involves three layers. These layers help maintain a
consistent and reliable flow of liquid while protecting the overall assembly from breaking
down as a result of wear or abrasion.

Inner tube: The inner tube is designed to be compatible with the liquid it carries,
allowing both free-flowing elasticity and pressure-resistant stress bearing. This tube is often
made from PDFE (PTFE), thermoplastic, or synthetic rubbers.

Reinforcement layer: This layer surrounds the inner tube and is composed of a coiled or
braided wire. This set up supports the tubing while protecting against tears.

Outer layer or Cover: This layer is made of rigid materials and is designed to protect the
innards of the hose.

Hydraulic Hose Compatibility: Temperature

Hydraulic hoses are exposed to two temperature concerns: internal liquid
temperature and external working temperature. As a result, hoses are rated for performance
in terms of both temperatures, with a maximum and minimum functioning temperature
rating. Exceeding these ratings can result in severely reduced working life or even failure, so it
is pertinent to use a hose that is properly rated to both the liquid temperature and the
environment temperature.

Hydraulic Hose Compatibility: Pressure

Hydraulic hoses are designed to withstand both an external and an internal pressure
minimum and maximum. Exceeding either of these ratings can severely affect hose
performance. Pressure ratings or recommendations for a specific type of hose are generally
available from the manufacturer.
Application Types:
With the above considerations about hose performance, it is also important to
understand other application necessities for hydraulic hoses. Because pipes and tubes are
generally more rigid, they can handle higher temperature or internal pressure in a given
application. However, this increased rigidity makes them much more difficult to use in a
moving operation. For instance, a construction digger requires a hydraulic system to operate a
digging tool, but the freedom of movement needed to operate the tool can place limitations
on hydraulic connections. A hydraulic pipe can allow torque, flexibility and elasticity in tool
arm movement that is unavailable with tubes or pipes.

Choosing a Hydraulic Hose:

Hydraulic hose users have a number of temperature, size and pressure factors to
consider when choosing a hose for an application. There is a helpful acronym to track all of
these considerations—STAMPED.

 Size: The important sizes for a hose are inside diameter (ID), outside diameter (OD), and
length.

 Temperature: Most hose materials have a working temperature range.

 Application: Many hydraulic hose applications involve bending, and thus hoses are rated
for minimum radius bend. This rating refers to how much the hose can bend,
contracting the flow space within the hose.

 Material: Compatibility charts are available for hydraulic hoses, usually from the
manufacturer or in third-party reference guides.

 Pressure: Hoses are rated for maximum system pressure. It is important that hose
application intentions include pressure spikes.

 Ends: “Ends” refer to the ends of a hose designed for connection, otherwise known as
“couplings.” Permanent couplings are designed for attachment to a pre-determined
connection. Field-attachable couplings require a user to use crimpers to seal the
coupling to a connection.

 Duplication (or Delivery): This guideline refers to long-term thinking about how easily a
hose is replaced. A very specific or proprietary hose may be more difficult to replace
than a widely available generic version. Some hoses wear out quickly due to the nature
of their application, and replacement should be considered before settling on a hose
type.