Components, Systems and Service for Rotating Equipment in ...
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Components, Systems and Service for Rotating Equipment in Process Technology EN 10.165.1/07.21
Transcript of Components, Systems and Service for Rotating Equipment in ...
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Components, Systems and Service for Rotating Equipment in Process Technology
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COMPONENTS
SUB-SYSTEMS
CUSTOMERS
CUSTOMERS
Compressors Pumps
Valve control
Mechanical seals
Cylinders
Pumps
Lubrication systems
Gas filtration
Gas panel Seal gas filtration
Global and yet local.With over 9500 employees worldwide, HYDAC is one of the leading suppliers of fluid technology, hydraulic and electronic equipment.Our wide range of products, combined with our know-how in development, production, sales and service, enables the diverse requirements of rotating equipment to be met worldwide.Our quality and environment certification to ISO 9001/2000 and ISO 14001 denote first class quality and responsible management of our resources.HYDAC system solutions One supplier. One contact. Wherever you need us, we are there to help you find the most effective solution – for every application, from components to a complete system.Reliable, thanks to internationally certified quality.Global standards or regulations such as: Pressure Equipment Directive 97/23/EC, Machinery Directive 2006/42/EC, ASME VII Div. 1, ATEX, and many more.
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YOUR PROFESSIONALPARTNER In the chemicals industry, rotating equipment includes all types of compressors and process pumps as well as turbines and turbo expanders.In recent times, the chemicals industry has been faced with demands to produce their products in a more environmentally friendly way, which ideally involves offsetting any resources used. This is a trend which is set to continue. More and more product cycles are implementing recycling techniques, and gas that is already pressurised is used either to drive other rotating equipment or generate power. For the systems used, this means constant product optimisation, even at a component level. Optimised and integrated product solutions and sustainable reductions in system costs become necessary. For this reason, HYDAC provides a comprehensive technology, product and service portfolio covering all aspects of rotating equipment.In this regard, HYDAC’s key focus is on providing a complete fluid technology approach for our customers in the form of system solutions. We are already supplying these integrated product and service solutions in all sectors of industry. Needless to say, an important part of an integrated solution in fluid technology is a comprehensive product range for service tasks such as fluid monitoring and conditioning. Providing service units, measuring equipment and manpower for service assignments across the globe also forms part of our business.Be it lubrication systems, gas panels, pulsation dampers for dosing pumps, supplying control oil for turbines or the electric or electro-hydraulic adjustment of fittings, HYDAC supplies components and systems for the wide variety of tasks – with our know-how, we can find a suitable solution.
Valves and valve blocks
Hydraulic accumulators
Fittings & ball valves
Mounting technology
Filtration
Heat exchangers & coolers
Sensors
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Explosion Protection ATEX - Marking
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2 3 4II 2 G
5 6 7 8 9EX ta IIIC T80 °C Db
5 6 7 8 9 10EX h IIC T6 Gb X
Marking in acc. with ATEX Directive 2014/34/EU Marking in acc. with EN standards
1. Official inspection authorities (selection) Only required if equipment was certified by a notified body
Notified bodies Country ID numberTÜV Rheinland Germany 0035TÜV Nord Cert Germany 0044INERIS France 0080LCIE France 0081PTB Germany 0102TÜV Süd Germany 0123DEKRA EXAM Germany 0158DEKRA B.V. The Netherlands 0344SP Sweden 0402SIRA UK 0518VTT Finland 0537BAM Germany 0589CESI Italy 0722SGS BASEEFA UK 1180SGS-TÜV Saar Germany 1637
6. Types of ignition protection
Ignition protection types, electric Symbol Standard
Flameproof enclosure d EN 60079-1
Pressurised enclosure p EN 60079-2
Powder filling q EN 60079-5
Liquid immersion o EN 60079-6
Increased safety e EN 60079-7
Intrinsic safety i EN 60079-11
Electrical equipment Ignition protection type “n” n_ EN 60079-15
Encapsulation m EN 60079-18
Devices with optical radiation op EN 60079-28
Protection by enclosure t EN 60079-31
Ignition protection types, non-electric Symbol Standard
Flow restricting enclosure fr EN 13463-2
Flameproof enclosure d EN 13463-3
Constructional safety "c" h EN 80079-37
Control of ignition source "b" h EN 80079-37
Liquid immersion "k" h EN 80079-37
2. Equipment groups
Equipment group I: Equipment intended for use in underground parts of mi-nes, and in those parts of surface installations of such mines, liable to be endangered by firedamp and/or com-bustible dust
Equipment group II: Equipment intended for use in other areas that could be at risk of an explosive atmosphere
4. Types of explosive atmosphere
G (gas): Mixture or gases, vapours or mists and air
D (dust): Dust-air mixture
10. Restrictions for equipment
X: indicates special conditions
U: Ex component with sub-certification, not to be used on its own
3. Equipment categories
Equipment category M1: Mining – very high level of safety
Equipment category M2: Mining – high level of safety
Equipment category 1: Very high level of safety
Equipment category 2: High level of safety
Equipment category 3: Normal level of safety
5.
EX symbol
9. Equipment protection level (EPL)
EPL Category/type of atmosphereMa M1Mb M2Ga 1 GGb 2 GGc 3 GDa 1 DDb 2 DDc 3 D
7. Groups
Gas groups Typical gasesII A PropaneII B EthyleneII C Hydrogen
Dust groups DefinitionIII A Flammable substancesIII B Non-conductive dustIII C Conductive dust
8. Temperature classes
Temperature class, gas Max. surface temperature in °C
T1 450T2 300T3 200T4 135T5 100T6 85In dust ex. area the max. surface temperature is stated directly
Non-electrical equipment
Electrical equipment
Subject to modifications
Ignition source
Oxygen
Flam
mab
le s
ubst
ance
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Explosion Protection
Directives and basic principles
IMSIntegriertesManagement System
IntegratedManagement System
Rev. 07
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O 9001 ISO 14001
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/EN
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Machinery Directive2006/42/ec
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Information on Implementation
and Application
LUBRICATION SYSTEMS z For gear lubrication and cooling zWith lifting systems for supplying mechanical seals zWith bladder and piston accumulator stations for emergency lubrication
Standard, modular oil supply system
z 50–250 litre as a lubricating oil system module
zUp to 100000 litre tank volume as a customised solution
Oil systems according to API zChapter 2 (special applications with high safety requirements) zChapter 3 (normal hazard level)
Systems – Rotating EquipmentHYDAC builds lubrication and cooling systems, oil supply systems for mechanical seals and systems for the conditioning or control of the seal gas for dry gas seals, and supplies them worldwide. Furthermore, HYDAC can produce both electro-hydraulic complete systems comprising of power units and servo-cylinders as well as electric cylinders for fittings.
MECHANICAL SEALS z Lubricating and cooling system for the mechanical seals zAccording to API 53 B zWith ribbed piping with free or forced air convection zStainless steel or carbon steel bladder accumulator
SEAL GAS zAccording to API 614 Chapter 4 z For closed-loop control and monitoring of the pressure and flow rate of the seal gas z For uninterrupted, continuous use even under critical conditions zWith HYDAC gas particle filter, gas coalescer filters
CONTROL OF FITTINGS zEHC electro-hydraulic safety controls according to IEC 61508 and IEC 61511 zEHC-S safety controls, modular design using standard components (SIL-enabled) zEHC-A drive concepts, also available as EHC-AA stand-alone drives (SIL-enabled) zEHC-U electro-hydraulic oil supply zHEZ electric cylinders
Bypass station EHC-U
ActuatorEHC-A
Electric cylindersHEZ
Further information on explosion protection can be found at www.hydac.com under brochure number EN 2.002.1.../…
Further information on the Machinery Directive can be found at www.hydac.com under brochure number EN 13.100.0.../…
Further information on the integrated management manual can be found at www.hydac.com under brochure number DE/EN 13.000.3/…
International Safety Standards
In sectors such as the chemical and pharmaceutical industries, in mining, in the production of crude oil and natural gas and in the food industry (particularly in mills), flammable substances are worked with in various processing and manufacturing procedures. This means that dangerous situations continually arise that can result in explosions and jeopardise people’s safety.Systems that are under high pressure are also worked with. These systems may be filled with toxic or explosive media. Accidents have often occurred and keep on occurring with these pressure vessels. To counter this danger, international standards and legal frameworks have been created that describe the design, materials, construction and monitoring of systems and components. These include, for example, the Machinery Directive, the Pressure Equipment Directive, the ATEX and IECEx explosion protection directives, ISO standards, ASME VIII Div. 1 and API.As a company with many years of global experience in components and system construction, HYDAC meets all the required national and international standards, which are particularly necessary in this industry.
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TEMPERATURETemperature transmitters:e.g. for temperature monitoring of top drive lubrication systems
zDesign: standard, intrinsically safe, flameproof enclosure, non-sparking zATEX, IECEx, CCSAUS approvals zCAN, HART, IO-Link interface, analogue output signal
COMPRESSOR CONTROLCompressor control EHC-D (digital control)
FLUID LEVELLevel sensors:
zDesigns based on capacitive, magnetostrictive and ultrasonic measurement zCAN, IO-Link interface, analogue output signal
PRESSUREPressure transmitters:e.g. for monitoring and closed-loop control of pressures in WHCPs
zDesign: standard, intrinsically safe, flameproof enclosure, non-sparking zDesigns specifically for hydrogen applications zATEX, IECEx, CCSAUS approvals zCAN, HART, IO-Link interface, analogue output signal
Pressure sensors for applications with increased functional safety:
zCertification up to SIL 2 (IEC 61508) or PL d (EN ISO 13849-1)
FLOW RATEFlow rate transmitters and flow switches:
zDesign: standard, intrinsically safe, flameproof enclosure, non-sparking zATEX, IECEx, CCSAUS approvals zHART protocol, analogue output signal
Steel and stainless steel ball valves z For shutting off gases, chemicals, paints, water etc. zOperating pressure up to maximum 500 bar zNominal sizes 4–200
HY-ROS Mounting Technology zExtensive range of mounting equipment for pipes, hoses and components
Threaded connections, test couplings, quick release couplings, coaxial valves
From mounting to tank accessories: pump accessories (bell housings, etc.)
In process technology, the processes have been automated for decades. Sensors and closed-loop control play a central role here.HYDAC supplies sensors to measure, among other things, pressure, temperature, flow rate and fill level for fluids and gases. Sensors specifically designed for hydrogen are also available.These sensors are available as simple standard sensors with 0 to 10 V or 4 to 20 mA analogue output and as versions with a wide range of digital interfaces.A malfunction in individual components can lead to the failure of an entire process or even endanger human life. To fulfil the special requirements in this context, HYDAC supplies sensors for applications with increased functional safety up to SIL 2/PL d. Many plants and systems, such as process pumps, compressors and turbines, are operated in potentially explosive atmospheres. A large number of sensors suitable for use in potentially explosive atmospheres are therefore available. Approvals in accordance with ATEX, IECEx and CCSAUS, and in some cases, multiple approvals, enable sensors to be used universally and worldwide.
Accessories Sensors and Control Technology
Fluid level gauge z Level switch z < 381 mm
U-bolt clamp z Ø up to 762 mm zA4 zPipe mounting
Large selection of ball valves in stainless steel
zPressure up to 1034 bar / 15000 PSI z 316Ti z Flexible adapter system
Coaxial valve zDiameter up to 50 mm, 100 bar zDirect acting zExplosion protection for shutting off and controlling low-viscosity liquids and gases
Mounting clamps DIN3015 with sacrificial anode
zDiameter up to 406 zPipe service life up to 20 times longer for systems in corrosive environments
Clamping bands zDiameter up to 762 mm zDiameter 6 to 56 mm zA4 bolts
Examples
Examples
In the construction of compressors and their auxiliary systems, a large number of pipes and cables need to be laid and secured, the fluid level of lubrication and hydraulic tanks / tanks installed high up checked, pipes connected, pumps coupled with motors and gas or fluid flows shut off and controlled.HYDAC Accessories supplies a wide variety of products for standard applications and applications with special requirements.
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Fluid Filtration – Degassing – Oil Mist
Inline filter RFLD zGrey cast iron zBall, segment and flap as switch fitting zUp to 63 bar zUp to 15000 l/min
Optimised filter element for applications including:
z Turbine lubrication, compressors, lifting units in turbines zStat-Free® technology included
Standard clogging indicator zVacuum, return-line and differential pressure indicators zPressure ranges up to 420 bar zSteel and aluminium
Inline filter AFLD to API 614 zSteel or stainless steel z 3/2-way ball valve as switch fitting zUp to 40 bar zUp to 1700 l/min
Hazardous area clogging indicator
zPressure ratings: 450, 700, 1035 bar zStainless steel zCan be turned through 360° z IP66 and IP67
Stat-X® to prevent electrostatic charging in highly critical hydraulic and lubrication applications
Hydraulic filters, bypass filters, breather filters and filter elements with high filtration performance and simple handling for safe and cost-effective system operation
High quality filter element technology that is constantly improved by our field experience, research and development
Some examples of what HYDAC offers
FILTERS FILTER ELEMENTS CLOGGING INDICATORS
1. FILTRATIONIn addition to cooling, filtration is the main task performed by a lubricating system in rotating equipment. HYDAC has been a leading company in filtration for decades.
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Duplex versionSingle version
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Special applications
STENO Compact enables decentralised extraction zNo power loss caused by long piping zConvenient adjustment and instant monitoring of the negative pressure z In the event of bearing damage, the damaged bearing can be identified precisely
Standardised series as single and duplex version z 25 m³/h to 265 m³/h zCarbon steel and stainless steel zAlso available with explosion protection
Ball valves, oil mist separator zSTENO 100 (single version) also in explosion-proof version/ATEX and certificates
These simulations are supplemented by in-house laboratory measurements with specially developed measuring procedures.
RT-Filtertechnik GmbH has developed a design that enables a tank reduction of more than 50%. These components have already helped many customers to alleviate their degassing problems.
Elaborate simulations are performed to determine the correct tank shape.
2. DEGASSING STRAINERBefore the oil is pumped back into the customer's system, lubrication oil systems need to ensure that any entrapped air is removed as well as any particles or heat that has entered. With the products from RT-Filtertechnik GmbH, HYDAC makes it possible to accelerate the degassing process to such an extent that tank sizes can be drastically reduced. This means that the system’s footprint can be made smaller and less oil needs to be used, resulting in financial savings as well as a reduced environmental impact.
Standard
3. OIL MIST SEPARATOR STENOOil mist separators are a major component of lubricating oil systems in turbines, such as gas and steam turbines.In the bearings of these turbines, a fine oil mist is formed from the lubricant. The escape of this oil mist through the seals of the bearings must be prevented. The oil mist separators are used to extract the air from the bearings and filter out the fine oil mist. Once recovered and filtered, the lubricant finally returns to the lubricating oil tank via a drainage layer.
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The OLF 15/30/45/60 series of filtration units are robust offline filters for industrial applications in hydraulic and lubrication systems with a large oil volume. The Dimicron® filter elements used in these filters are characterised by their particularly high contamination retention capacity and an environmentally safe method of disposal (incinerable).Rotating equipment that either has to work in a humid environment or has steam as its process gas suffers from excess entry of process steam and water into the oil circuit.This results in a rapid acceleration in fluid ageing and limited lubricity. Using FAM dewatering and filtration units continuously throughout operation guarantees comprehensive conditioning of the lubrication media.As these units sometimes have to work in explosive environments, like any other oil conditioning system, HYDAC also supplies the entire range as an ATEX series.The Varnish Mitigation Unit VMU and Varnish Elimination Unit VEU are used to prepare mineral oils. They are particularly effective at removing oil degradation products (varnish) from mineral oils. The removal of varnish is based on adsorption on an active surface.
Fluid sensors zCS series for recording cleanliness classes to ISO 4406 zAS AquaSensors for recording the relative saturation level of water in the oil and the temperature zHYDACLAB® sensors to measure the oil condition (temperature, saturation level, electrical conductivity and how it changes, dielectric constant and how it changes)
Gas Filtration
Seal gas zDry gas seals of turbo machines are very complex systems and extremely sensitive to contamination by solid particles, aerosols and condensates. As the shaft rotates, a tiny gap (roughly 3 µm) forms on the seal ring through which the seal gas flows. To protect this seal, the seal gases must be filtered appropriately to ensure the seal has as long a service life as possible. Examples
From standard to special applications
Oil Monitoring and Conditioning
Type GxF and GF3 seal gas filters for turbocompressors OLF
FAM 5
VEU VMU series
In-house filter element technology z Fine filtration, coalescence, glass and metal fibre
Examples
Gas Coalescer Filter GCF – problem-solver for dry gas seals
zWith cyclone separator zDouble shut off and vent valves zATEX
Type GFLx, GxF and GF3 process gas filters for screw and diaphragm compressors
Process gas z In some compressor types (e.g. piston or screw compressors), fluids are injected to lubricate and cool surfaces that rub against each other. These fluids later need to be removed with coalescer filters.
PROCESS AND GAS FILTERSTo function optimally, compressors need clean and dry gas. If pre-filtration is insufficient, solids and aerosols can enter the system unhindered, causing wear and abrasion. Gas turbine injection nozzles, turbocompressor rotor blades and dry gas seals can become damaged, and water hammer may even occur in the piston compressor. HYDAC supplies a broad spectrum of gas filters for all applications, both for seal gas and in the process gas flow, with filter element technology developed in-house.
FILTER SYSTEMSThe service life of the goods, materials and fluids used in the entire process can only be guaranteed in the long term if they are considered as a whole, across the entire operating life. It goes without saying that this can also help to increase environmental protection while reducing the operating costs.For example, the longer service life of lubricants and hydraulic fluids in a power plant can often bring about cost savings of 30% and reduce the carbon footprint (producing just one litre of turbine oil creates roughly 700 g CO2).As a specialist in fluid engineering, HYDAC can provide continuous online monitoring of your operating fluids (lubricants, hydraulic fluids) and, as required, process-controlled conditioning of these operating media with application-optimised cooling, filtration and fluid regeneration.
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Block solution comprising of a non-return valve, safety valve, temperature and pressure control plus sensors
Closed loop blockA static pressure is kept constant by a hydraulic accumulator (generally a 50-litre bladder accumulator)
Valves and Valve Blocks
Pressure relief valve DB12120A-CEBlock solutions for lubrication systems help to drastically reduce piping costs.Block with non-return valve, excess pressure safety function, pressure regulator valve and connections for pressure, temperature and oil-quality sensor
zUp to 10 bar zUp to 50 l/minBlocks for controlling fittings
Block combination
Pressure relief valve
Modular system
VALVE TECHNOLOGY AND VALVE BLOCK TECHNOLOGYHYDAC supplies components, modules, sub-systems, entire drive units and controls including electronics. The valve technology includes cartridge valve technology, an extensive range of industrial valves and logic valves. The individual components are combined in specially developed valve blocks for specific applications.
Examples
Block Solutions for Lubrication Systems
Distribution of the flow rate and pressure control
Open loop blockConstant pressure with simultaneous circulation of the sealing oil
Pressure relief valve DB12120A-CE zCE valve according to Pressure Equipment Directive (PED) 2014/68/EU z TÜV type approved z Low hysteresis and accurate pressure control zExcellent stability throughout the entire flow range zVarious pressure ratings up to 400 bar, up to 110 l/min
Modular system z Installation on EHC-A zOperating pressure 210 bar
Options zRetract piston rod zExtend piston rod zRelease proportional valve zSet maximum pressure ... and much more
Electrohydraulic safety control system Process technology plants need to be operated “safely” as they pose an increased hazard risk for humans and the environment. When corresponding protective strategies are developed, one of the things that is focused on is the control valves and how they are controlled with safety functions.The architecture of safety-related control, e.g. for the overspeed protection of a turbine needed to achieve the specified Safety Integrity Level (SIL), is set down in IEC 61508 (type: EHC-S 2003 plus).
zBlock combination, sealing oil system zProportional sealing pressure control for mechanical seals z Two main types of valve manifolds
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HYDAC INTERNATIONAL
SAF safety and shut-off block for shutting off, securing and discharging hydraulic accumulators, also with ATEX approval
zUp to Ø 50 mm zUp to 1000 bar zCarbon steel and stainless steel
HYDAC INTERNATIONAL
Accumulators
External gear pumps for open loop hydraulic systems (type: PGE)
zDisplacement z 0.25–60 cm³/rev zDrive speed up to max. 3500 rpm
Some examples of standard and customer-specific applications
Pumps
Axial piston pump series for open loop hydraulic systems (type: PPV100M)
zDisplacement z 18.6–100.7 cm³/rev zDrive speed up to max. 2250 rpm
Diaphragm accumulator as pulsation damper (dosing pumps) in a weld version or screw version
zUp to 400 bar zUp to 4 litres
Piston accumulator for safety function
zUp to 1000 bar zUp to 3300 litres
Bladder accumulator as safety function EHC
zUp to 550 bar zUp to 200 litres
Low-pressure bladder accumulator for lubricating oil systems
zUp to 40 bar zUp to 450 litres
BIS bladder integrity indicator detects a defective bladder during operation
z p0-Guard available as an option
As accumulators are sensitive components in safety systems, HYDAC has developed multiple monitoring systems for all accumulator types
zMonitoring systems with selective or continuous measurement
Stainless steel bladder accumulator (up to 1000 bar) for special customer requirements and mechanical seals
Internal gear pumps for open loop hydraulic systems (type: PGI)
zDisplacement z 3.8–249.9 cm³/rev zDrive speed up to max. 4200 rpm
VARIABLE-SPEED DRIVESHYDAC supplies variable-speed drives for the hydraulic system as well as the lubricating system. This is a perfect example of symbiosis between hydraulics and electromechanics. Thanks to condition-optimised adjustment of the solutions, power dissipation is reduced to a minimum. In lubricating systems, for example, there is no need to use pressure reducing valves to control the pressure and complicated control pumps can be replaced by this solution, which is technically much simpler.
Product features, DVA-Kit, standard range zDrive power up to 22 kW zOperating pressure up to 210 bar z Flow rates up to 100 l/min z Integrated regulation of pressure or flow rate z Logic functions can be realised z 4 digital / 2 analogue inputs (pressure/flow sensor can be connected) z 2 digital / 1 analogue output zNo switch cabinet needed z Input voltage: 3~200 – 480 V, 47 – 63 Hz z IP55
Examples
USE IN PROCESS TECHNOLOGYApplications include energy storage and pulsation damping in dosing pumps, suction flow stabilisers on the suction side of pumps and use in loading stations/refineries for shock absorption when valves close or in piping.Accumulators also actuate sensitive sub-systems, for example emergency closing valves in an emergency, so that they can be supplied with pressurised oil and always function. Accumulators are also used for emergency lubrication of plain bearings and mechanical seals, so that when there is a switch from a defective pump to an alternative one, there is no pressure drop and these components remain free from damage.As not every accumulator is equally suitable for every application, it is vital for all possible technologies to be supplied. HYDAC is the world’s only supplier to offer bladder, diaphragm, piston and even metal bellows accumulators produced in-house.
GEAR PUMPSHYDAC pumps are used to lift heavy turbines or compressors in lubricating oil systems. They also provide pressure and flow in the control hydraulics of pipe fittings and for the driving of piston compressors.
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Standard HEZ series z Trapezoid, ball, planetary roller screw zUp to 80 mm diameter z 130 kN z 720 mm/sec
To control the HEZ electric cylinders, there are several variants to choose from
zWith safety functions zWith pump, motor, inverter
Cylinders
ExamplesDrive cylinder, zone cylinder or direction cylinder with water cooling
zUp to 1 m in length
ELECTRIC CYLINDERSAs they are easy to integrate and need no maintenance, HYDAC electric cylinders (HEZ) allow simple implementation of linear movements. In an HEZ unit, the rotation of the unit’s electric motor is converted into a linear movement using a screw drive. The gear and the drive can be selected to produce various positioning forces, speeds and duty cycles. They are particularly suitable for use in applications where only individual drives are needed.
Electro-hydraulic drive system for functional safety in a water/steam circuit
Coolers
Air cooler AC-LN MI 8-14 z Low-noise air cooler with axial fan zWith integrated frequency inverter zContinuously adjustable speed-control in accordance with the fluid temperature in the cooling element zRegulated cooling capacity z 50 – 230 kW
Plate heat exchangers – brazed (HEX Sxxx)
zStainless steel, vacuum-brazed with copper or nickel zUp to max. 30 bar zUp to max. 300 kW
Plate heat exchangers – gasketed (Hxxx-LIQUID)
zStainless steel, SMO, titanium z 10, 16, 25 bar zUp to max. 30000 kW
Pump-transfer Cooler Filtration Units UKF 1–3 for gearbox applications
z For cooling and lubrication zStationary gears zWith gear pump and filter z Flow rate: up to 80 l/min zCooling capacity: up to max. 75 kW
For steam to drive a steam turbine, for example, the process pipe fittings used in connection with rotating equipment need to be actuated and the flow needs to be controlled. This is performed by cylinders in HYDAC’s EHC drive system (see page 4).
In all hydraulic and lubrication systems, the heat in the gearboxes, plain bearing seals etc. in the rotating equipment needs to be channelled away. The task of cooling systems is to dissipate the heat.Efficient cooling systems can help to lengthen the service life of the operating fluids and filters used and reduce life cycle costs (LCCs). The HYDAC product portfolio includes coolers, heat exchangers and cooling systems. We can also cool electric drives and motors, generators, inverters and transformers. Our cooling systems enable gearboxes to be cooled and lubricated. Whether your cooling involves air or water, return flow or bypass flow, standard or customised solutions – we are always happy to help.
Examples
Stand-alone EX-protection actuator with safety function
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Monitoring of z Pressure z Temperature z Level z Flow rate z Vibration
Operating Condition
ComponentConditionMonitoring of
z Pumps z Valves z Filters z Accumulators z Coolers z Machine
Elements
Monitoring of z Solid Particles z Wear z Water Saturation z Oil Condition
FluidCondition
Bladder IntegritySystem BIS 1000
Electronic PressureSwitch p0-GuardEDS 3400 p0
Contamination SensorEY 1356
Electronic Diff erentialPressure Transmitter HPT 500
Vibration SensorVS 3000
Oil sample
AquaSensorAS 1000
ContaminationSensorCS 1000
MetallicContamination SensorMCS 1000
HYDACLab ®HLB 1400
Flow RateTransmitterEVS 3110
ElectronicLevel SwitchENS 3000
ElectronicTemperature TransmitterETS 4000
Electronic Pressure TransmitterHDA 4000
Integration into existingprocess control unit /monitoring system
Spare Parts
Service / Maintenance
Display / Confi guration
Industrial AnalyticsTrend Analysis, Limit Analysis, ...
Proactive Maintenance /Fluidengineering
Maintenance System● SCADA System ● Vibration Monitoring System● PLC● PC / Industrial PC
Server
Experts Analysis
Lab Report
CMX / FluMoS Expert
- RS 485- USB 2.0- CAN- 2 x RJ45 Ethernet- WLAN / Bluetooth (optional)
KineSys Data+
- 2 x HSI smart- 4 x analog
Condition SensorInterfaceCSI-C-11
- 3 x HSI smart (RS485)- 10 x analog- 2 x vibration (IEPE)- 1 x frequency (rpm)
MachineConditionMonitoring SystemMCMS 2000
40181 700928
CONDITION MONITORINGProducts and their applicationsIn hydraulic and lubrication oil systems, friction, wear, leakage and excess temperatures can contribute to the operating fluid becoming contaminated, with solid particle contamination or water, for example. This contamination then goes on to cause errors in components and subsystems and ultimately in the system as a whole. Furthermore, the normal ageing process of the fluid causes performance losses that often result in system downtimes.In order to prevent these time-consuming and costly consequences, monitoring the condition of the operating fluid is of major significance. The condition of the operating fluid is comparable to a “fingerprint” of the overall condition of the system. Implementing a predictive maintenance strategy allows the service life of all critical machine elements to be fully utilised by detecting a variation from the fluid’s normal condition early on. This is the basis for a significant reduction in operating costs as costly, unplanned system downtime can be eliminated or minimised. As soon as the beginnings of a variation are detected, countermeasures can be taken promptly. The remaining service life of the relevant component can be monitored while production continues. Meanwhile, spare parts can be procured and maintenance can be scheduled with minimal costs.A predictive maintenance strategy therefore allows available resources to be utilised optimally, reducing the total costs for the machinery throughout its service life (life cycle cost or LCC).
Expertise and Service
FLUIDCARECENTERRely on the highest level of quality and innovationDevelopment at HYDAC means designing application-orientated filtration systems based on test results from our research laboratories, test laboratories and on-site analyses, whilst taking the requirements of the user and the manufacturer into account.
At the HYDAC FluidCareCenter, we collaborate with our customers to develop innovative projects in a wide range of industries. A skilled development system using state-of-the-art computer-aided analysis, measuring and testing equipment and test rigs ensures prompt implementation of the project.
Service worldwide – your key to higher process reliability and system availabilityThe HYDAC ServiCenter offers a systematic, comprehensive range of services, with objective maintenance and inspection procedures that significantly help to increase the useful life of hydraulic systems, lubrication systems and electrohydraulic open- and closed-loop controls.After an in-depth consultation, you can create a service package tailored to your needs.Whether it be support of existing in-house maintenance or sub-contracting a complete maintenance package, we will always find the best solution.
Rental serviceWhen equipment is only required for short periods, there is understandable opposition to making any costly investment. On the other hand, a rental or loan device is often the cheaper and more flexible alternative. Anytime you need a filtration unit, dewatering unit, flushing unit, measurement device or nitrogen charging unit – we have one ready for you!All units for hire are regularly maintained and checked so that they are always reliable and ready for operation.Right from the outset our specialists will be pleased to advise you on selecting the best unit for your application. We will ensure that the hire equipment will be available reliably, and therefore that your project runs smoothly.
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Strengthening your Image and Spare Parts Strategy
QUALITY PROTECTIONWith the help of numerous quality protection interfaces, HYDAC supports leading OEMs in strengthening their reputation and spare parts strategy. Increased element sales in the aftermarket will not only benefit you financially but will also establish your image as a good quality brand.The interfaces ensure that only original filter elements can be installed in the machines, ensuring reliable component protection in the long term. Imitation filter elements with poor quality and often greatly reduced element service lives don’t stand a chance. With this strategy, the OEM is perceived as a first-class quality supplier.
BRAND LABELLINGAn additional measure for strengthening the spare parts strategy of OEMs is brand labelling: the innovative outer casing of the filter elements can be used as an advertising medium to promote the brands of leading OEMs. With multicolour printing as an option, there are no limits. Contact us to discuss your choice of design!
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Global Presence.Local Expertise.www.hydac.com
HYDAC INTERNATIONAL GMBH
Industriegebiet 66280 Sulzbach/Saar GermanyTelephone: +49 6897 509-01Fax: +49 6897 [email protected] www.hydac.com
NOTEThe information in this brochure relates to the operating conditions and applications described. For applications and operating conditions not described, please contact the relevant technical department.Subject to technical modifications.
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