HYDRAULIC / PNEUMATIC - · PDF filehydraulic / pneumatic ... 1/7/2017 naarso 3 . before you...
Transcript of HYDRAULIC / PNEUMATIC - · PDF filehydraulic / pneumatic ... 1/7/2017 naarso 3 . before you...
HYDRAULIC / PNEUMATIC
JOSEPH J. PANDOLFO N.A.A.R.S.O. 2017
[email protected] 570-350-3359
1/7/2017 NAARSO 2
1/7/2017 NAARSO 3
BEFORE YOU DO ANYTHING ON OR WITH A
PNEUMATIC/HYDRAULIC SYSTEM
DO THE FOLLOWING!!!
1/7/2017 NAARSO 4
1/7/2017 NAARSO 5
LOCK OUT/TAG OUT DE ENERGIZE IT
BLEED IT OFF KILL IT DEAD.
OR IT WILL KILL YOU!!!
1/7/2017 NAARSO 6
1/7/2017 NAARSO 7
8
WHAT IS IT?
1/7/2017 NAARSO
9
NOT WHAT YOU THOUGHT.
1/7/2017 NAARSO
ANSI NFPA/JIC T2.24.1 + ISO 4413
1/7/2017 NAARSO 10
1/7/2017 NAARSO 11
1/7/2017 NAARSO 12
1/7/2017 NAARSO 13
A high-pressure jet that sprays hydraulic oil
constitutes a physical danger and an
environmental problem
1/7/2017 NAARSO 14
1/7/2017 NAARSO 15
HYDRAULIC SYSTEM: OIL FROM A TANK FLOWS THROUGH A
TUBE OR PIPE,INTO A PUMP. THE PUMP INCREASES THE PRESSURE OF
THE OIL. THE OIL IS MOVED TO A CYLINDER MOVING A PISTON,THERE BY DOING A JOB
OR MOVING A LOAD.
1/7/2017 NAARSO 16
PNEUMATIC SYSTEM AIR FROM THE ATMOSPHERE IS
PULLED INTO AN AIR COMPRESSOR. THE COMPRESSOR INCREASES THE
PRESSURE OF THE AIR IT IS DISCHARGED TO A PISTON MOVING IT TO DO A JOB,OR MOVE
A LOAD.
1/7/2017 NAARSO 17
BIG OR SMALL THE’RE ALL THE SAME. FLUID SYSTEM
OIL PUMP/AIR COMPRESSOR A DEVICE EITHER A PISTON OR A ROTATING
MEMBER DRIVEN BY THE FLUID. PIPING AND CONTROLS
1/7/2017 NAARSO 18
PRESSURE; FORCE PER UNIT AREA
[POUNDS PER SQUARE INCH]
1/7/2017 NAARSO 19
Pressure Gage
1/7/2017 NAARSO 20
PRESSURE AND TEMPERATURE 1/7/2017 NAARSO 21
1/7/2017 NAARSO 22
The HYDRAULIC
system 1/7/2017 NAARSO 23
1/7/2017 NAARSO 24
prime mover
1/7/2017 NAARSO 25
FLUID PUMP MECHANICAL ENERGY IS CONVERTED INTO
FLUID ENERGY
1/7/2017 NAARSO 26
hydraulic (pressure) energy
1/7/2017 NAARSO 27
FLUID MOTORS FLUID ENERGY IS CONVERTED TO
MECHANICAL WORK.
1/7/2017 NAARSO 28
1/7/2017 NAARSO 29
ACTUATORS DEVICE THAT CONVERTS FLUID ENERGY TO
MECHANICAL
1/7/2017 NAARSO 30
1/7/2017 NAARSO 31
PARTS OF THE SYSTEM PUMP
OIL RESERVOIR INTAKE FILTER
PRESSURE GAGE RELIEF VALVE
OUT PIPING
1/7/2017 NAARSO 32
HYDRAULIC SYSTEMS PUMPS
1.GEAR-TYPE 2.VANE-TYPE
ROTARY PISTON-TYPE 4.RECIPROCATING PISTON
1/7/2017 NAARSO 33
HYDRAULIC FLUIDS 1.PETROLEUM-BASE FLUIDS 2.SYNTHETIC-BASE FLUIDS
3.WATER
1/7/2017 NAARSO 34
FUNCTION OF FLUID 1.TRANSMISSION OF FLUID POWER
2.MEANS OF LUBRICATION 3.ACTS AS SEALANT
1/7/2017 NAARSO 35
TYPES OF 1.PENNSYLVANIA/PARAFFIN-BASE OILS
2.GULF COAST/NAPHTHENIC&ASPHALTIC 3.MIDCONTINENT/MIXED-BASE OILS
CONTAIN BOTH NAPHTHENIC &PARAFFIN
1/7/2017 NAARSO 36
1/7/2017 NAARSO 37
SYNTHETIC-BASE FIRE RESISTANT
SLUDGE/GUM REDUCED LITTLE EFFECT ON TEMPERATURE
1/7/2017 NAARSO 38
DIRECTIONAL CONTROL VALVES FUNCTION OF VALVE IS TO DIRECT OIL OR
AIR TO A GIVEN PLACE IN A SYSTEM.
1/7/2017 NAARSO 39
TYPES OF VALVES TWO WAY
TWO PORTS/TWO PASSAGES
THREE WAY THREE PORTS/THREE PASSAGES
FOUR WAY 4/4
1/7/2017 NAARSO 40
MANUAL CONTROL BY HAND OR FOOT/BODY PART
MECHANICAL OPERATION CAM/ROTARY-SWING-TRIP PIN
ELECTRICAL OPERATION MOTOR/SOLENOID
1/7/2017 NAARSO 41
PRESSURE CONTROL FUNCTION OF TO CONTROL PRESSURES IN
THE FLUID POWER SYSTEM. 1.RELIEF VALVE
2.REDUCING VALVE 3.SEQUENCE VALVE UNLOADING VALVE
1/7/2017 NAARSO 42
FLOW CONTROLS FUNCTION OF TO CONTROL THE VOLUME OF FLUID THAT PASSES`A CERTAIN POINT
IN A CIRCUIT. USED TO CONTROL
SPEED
1/7/2017 NAARSO 43
MANUAL CONTROL BY HAND OR FOOT/BODY PART
MECHANICAL OPERATION CAM/ROTARY-SWING-TRIP PIN
ELECTRICAL OPERATION MOTOR/SOLENOID
1/7/2017 NAARSO 44
TYPES OF 1.METERING-IN
2.METERING-OUT 3.METERING BOTH DIRECTIONS
4.BLEED OFF
1/7/2017 NAARSO 45
ACCUMULATORS STORAGE DEVICE
BATTERY CHEMICAL TO ELECTRICITY
PIPE WITH CAP ACTS AS A CUSHION
1/7/2017 NAARSO 46
1/7/2017 NAARSO 47
HYDRAULIC ACCUMULATORS
1.SHOCK ABSORBER 2.OIL MAKE UP
3.COMPENSATE FOR LEAKAGE 4.SOURCE OF EMERGENCY POWER
5.STEADY DELIVERY PRESSURE 6.TRANSFER BARRIER BETWEEN OIL AND
OTHER FLUID
1/7/2017 NAARSO 48
TYPES OF 1.WEIGHT-LOADED 2.SPRING-LOADED
3.AIR OR GAS NONSEPARATOR/SEPARATOR[DIAPHRAGM]
1/7/2017 NAARSO 49
1/7/2017 NAARSO 50
1/7/2017 NAARSO 51
TYPES OF CYLINDERS; 1.SINGLE -ACTING 2.SPRING -RETURN
3.DOUBLE-END 4.TANDEM 5.DUPLEX
TWO PISTONS/ROD INSIDE
1/7/2017 NAARSO 52
ROTATING & NONROTATING CYLINDERS
1/7/2017 NAARSO 53
safety valve
• n. • A valve in a pressure container, as in a
vessel, that automatically opens when pressure reaches a dangerous level.
• An outlet for the release of repressed energy or emotion.
1/7/2017 NAARSO 54
Safety valve
1/7/2017 NAARSO 55
The PNEUMATIC
system
1/7/2017 NAARSO 56
1/7/2017 NAARSO 57
AIR COMPRESSORS 1.POSITIVE-DISPLACEMENT/PRESSURE
2.VELOCITY/DYNAMIC
1/7/2017 NAARSO 58
1/7/2017 NAARSO 59
PARTS OF SYSTEM; AIR INTAKE
AFTERCOOLER WATER SEPARATOR
AIR RECEIVER AIR DISHARGE
1/7/2017 NAARSO 60
Air Receiver
1/7/2017 NAARSO 61
Aftercooler
Filter, Regulator, Lubricator
1/7/2017 NAARSO 62
PNEUMATIC MOTOR 1.ROTARY
2.RECIPROCATING
1/7/2017 NAARSO 63
AIR FILTERS REMOVE ALL FOREIGN MATTER
REGULATORS REDUCES OR REGULATES PRESSURE
LUBRICATORS STORES OIL
INJECTS OIL MIST OR FOG
1/7/2017 NAARSO 64
AIR FILTERS,REGULATORS, LUBRICATORS
1/7/2017 NAARSO 65
PIPING 1.RIGID
2.SEMI-RIGID/TUBING 3.FLEXIBLE/HOSE
1/7/2017 NAARSO 66
Hose Routing
Replacement hoses must be restrained,
protected, or guided (using clamps),
to minimize risk of damage due to excessive flexing and
whipping.
1/7/2017 NAARSO 67
1/7/2017 NAARSO 68
1/7/2017 NAARSO 69
1/7/2017 NAARSO 70
1/7/2017 NAARSO 71
Flared tube
1/7/2017 NAARSO 72
THE BAD GUYS DIRT HEAT
MISAPPLICATION IMPROPER FLUIDS
FAULTY INSTALLATION MAINTENANCE
1/7/2017 NAARSO 73
THE SAFE WAY IS THE ONLY WAY!
1/7/2017 NAARSO 74
A pressure vessel • a closed, rigid container designed to hold gases
or liquids at a pressure different from the ambient pressure.
1/7/2017 NAARSO 75
other examples of pressure vessels are:
• diving cylinder, recompression chamber, distillation towers, autoclaves nuclear reactor vessel, habitat of a space ship, habitat of a submarine, pneumatic reservoir, hydraulic reservoir under pressure, rail vehicle airbrake reservoir, road vehicle airbrake reservoir and storage vessels for liquefied gases such as ammonia, chlorine, propane, butane and LPG
1/7/2017 NAARSO 76
How about now?
1/7/2017 NAARSO 77
1/7/2017 NAARSO 78
Date of 1980 32 years old?
1/7/2017 NAARSO 79
VARIOUS TYPES OF CORROSION
• ATMOSPHERIC • GALVANIC • UNIFORM/GENERAL • PITTING • STRESS CORROSION CRACKING • CREVICE CORROSION • HIGH TEMPERATURE
1/7/2017 NAARSO 80
A RECIPE FOR RUST " Take 2 parts iron (FE).
Combine with 3 parts Oxygen (O). Add water and salt to taste.
Increase temperature to speed up process.
1/7/2017 NAARSO 81
1/7/2017 NAARSO 82
© QSI Training Services, Inc. 2004 all rights reserved 1/7/2017 NAARSO 83
MOTOR
8 QSI Training Services 2004 all rights reserved
1/7/2017 NAARSO 84
RELIEF Valve
© QSI Training Services, Inc. 2004 all rights reserved 1/7/2017 NAARSO 85
Some other IMPORTANT Components
Bladder Accumulator
DRY Nitrogen
Oil Check Valve
Flow Control Valve
8 QSI Training Services 2004 all rights reserved
1/7/2017 NAARSO 86
Filter or Strainer
1/7/2017 NAARSO 87
Pneumatics: Symbols
1/7/2017 NAARSO 88
HOSES AND THINGS
1/7/2017 NAARSO 90
1/7/2017 NAARSO 91
• Notice the hose coming off the top of the pump and going into the filter. It is bent in two planes. Most hose-specification literature recommends that hose not be bent in more than one plane. Doing so can cause uneven distribution of tension to reinforcing wires within the hose. As pressure pulsations occur in the hydraulic system, the overloaded strands undergo excessive tensile stress. After continuous cycling, the over-stressed strands can fail due to fatigue and eventually cause the hose to rupture. Worse yet, the failure can be catastrophic in nature, providing little or no warning of the impending failure.
1/7/2017 NAARSO 92
1/7/2017 NAARSO 93
PIPING FAILURES
• PRESSURE TOO HIGH. • NOT PROPERLY SUPPORTED • INCORRECTLY SIZED. TOO SMALL. • HARDENING OF COPPER TUBING.
1/7/2017 NAARSO 94
DEFINITION OF AN INDUSTRIAL HOSE
• An industrial hose is a flexible reinforced tube for conveying liquids, solids, and gases.
• A typical industrial hose is dragged, coiled, run over, kinked and subjected to all kinds
• of abuse. Therefore, the application and its environment must be taken into consideration
• for proper hose selection. Selection of the proper hose and materials will increase
• hose life, improve performance, and ensure safety. • Industrial hose is used for three purposes: • 1. To transfer gases, liquids, solids and mixtures of these materials. • 2. As a flexible connector to absorb surges and vibrations. • 3. As a conduit to protect other hose, pipes and wires.
1/7/2017 NAARSO 95
Three Basic Elements of a Hose
• Tube – Its purpose is to handle specific fluids or solids. It is the innermost rubber or
• plastic component of the hose that must be resistant to the material that it is intended
• to convey because it is the part of the hose in contact with the material. A variety of
• compounds can be used depending on the application. 1/7/2017 NAARSO 96
• Reinforcement – Its purpose is to withstand a specific amount of working pressure
• measured in pounds per square inch (psi) or Pascal (Pa) or vacuum (In Hg, inches of
• mercury). The reinforcement may consist of many layers of fabric, yarn or wire placed
• on top of the tube and referred to as “plies.”
1/7/2017 NAARSO 97
• Cover – Its primary purpose is to protect the tube and reinforcement from external factors
• such as ozone, weather, abrasion and heat. A variety of compounds can be used,
• depending on the application.
1/7/2017 NAARSO 98
Caution!
1. Hose should not be used in “out-of-sight”
applications, where the hose is buried, encased, or submerged .Use rigid pipe in those applications.
2. Hose has a finite service life and is not to be used in permanent applications.
1/7/2017 NAARSO 99
P R O P E R H O S E S E L E C T I O N
• Proper hose selection is the first step in preventive maintenance. Selecting the best
• product for the application will allow you to obtain the maximum life expectancy from
• the product for the best value.
1/7/2017 NAARSO 100
S - Size:
• I.D. (Inside Diameter) • O.D. (Outside Diameter) • Based on the machinery sizing. • Flow rate requirements (GPM for liquids;
CFM for gases).
1/7/2017 NAARSO 101
T - Temperature:
• Consider exterior and interior temperature, as well as
• temperature impact on the material being conveyed.
1/7/2017 NAARSO 102
A - Application: • Where will the hose be used? • How will the hose be used? • How often will the hose be used (continuous, intermittent, • seldom)? • What are the environmental conditions? • Special hose construction (crush resistant)? • Conductivity requirements? • Is the hose used in a critical application? • Government or Industrial Standard requirements? • Use hoses that are specifically designed for these applications: • Steam • LP Gas • Aircraft Ground Refueling • Corrosive Chemicals
1/7/2017 NAARSO 103
M - Material
• Chemical name(s) and state(s) - (liquid, solid or gas)
• Food • Dry or powder • Liquid
1/7/2017 NAARSO 104
P - Pressure
• What is the working pressure? • What is the maximum surge pressure? • Is there a vacuum?
1/7/2017 NAARSO 105
E - End requirements
• What type of thread ends? • Proper Coupling Selection ?
1/7/2017 NAARSO 106
H O S E I N S P E C T I O N S
• Periodic Inspections – • Planning for Safety and Maximum
Performance
1/7/2017 NAARSO 107
• Achieving safety and performance in the use of a hose requires periodic inspections of
• the hose and its fittings prior to, during and after use. Hoses that have become old,
• worn, or damaged can present a danger to individuals and to the environment. Hoses
• that are not properly maintained can fail which may result in costly material spills,
• cleanup, downtime and injury. Planned inspections, corrective actions, and hose replacements
• can be less expensive than replacement or repairs made after a failure occurs.
1/7/2017 NAARSO 108
When and how often should you inspect hose?
• Inspection requirements will vary with each application type. The following factors
• should be considered: • Critical nature of application • Operating temperatures • Operating pressures • Environmental factors 1/7/2017 NAARSO 109
•It is helpful to think of hose
inspection at two levels:
1/7/2017 NAARSO 110
Level 1 Inspection
• An inspection of hose on an on-going daily basis looking for signs such as:
1/7/2017 NAARSO 111
• 1. Hose cover damage. • Cuts, cracks, abrasion, exposed reinforcement, • etc. • 2. Stiffness or hardness of the hose. • As a hose ages and is exposed to sunlight, • ozone, extreme temperatures or chemicals • it can lose some of its resiliency and • become stiff and hard. When flexed, a stiffened • hose can crack, leading to a failure.
1/7/2017 NAARSO 112
• 3. Changes in color. • May indicate chemical attack. • Ozone or aging. • 4. Cover blisters. • Chemical incapability. • Permeation in the early stages of leakage. The
blister can break and expose reinforcement • that can degrade from contact with • environmental factors.
1/7/2017 NAARSO 113
• 5. Kinked or flattened hose. • Restricted material flow and hose • performance. • 6. Leakage. • Puddles or spilled material under the • hose assembly. • Problem with coupling interface or • attachment. • Weeping from the hose.
1/7/2017 NAARSO 114
• 7. Damaged hose reinforcement. • Weakened hose.
1/7/2017 NAARSO 115
Level 2 Inspection
• An inspection that requires equipment shutdown in order to conduct a more thorough evaluation
• of the hose in a safe manner.
1/7/2017 NAARSO 116
1. Visually inspect for leakage. • NEVER inspect a hose for leaks by running • your hand over it while it is under pressure • or contains the material being transferred. • Escaping fluid under high pressure can exert • enough force to penetrate and cut flesh, • causing painful and severe injury. • Hot materials and chemicals can cause serious • burns. • ALWAYS conduct close inspection of hose • when pressure is released and the hose does • not contain potentially dangerous material.
1/7/2017 NAARSO 117
2. Hydrostatic Pressure Testing
•Test at regular intervals. •Essential for hoses used in hazardous applications such as chemical, steam, petroleum and compressed gas transfer. •Always use water for pressure testing. •Never use flammable or corrosive fluids or compressed gas
1/7/2017 NAARSO 118
RMA HYDROSTATIC TESTING PROCEDURES
• All hose and couplings should be hydrostatic tested at regular intervals. • Intervals for testing vary with each hose type. • Procedure: • 1. The hose should be at room temperature. • 2. The testing area should be clean and dry. • 3. Lay the hose out straight to its full length. • 4. Place the hose on rollers. This allows the hose to be moved while under pressure. • 5. Restrain the hose if there is danger of uncontrolled movement during the test. • 6. Conduct a visual inspection. • Look for cuts, gouges, bulges, soft spots, coupling slippage or any signs of wear or • failure. • 7. A hose which does not pass a visual inspection should be replaced. • 8. A hose which does pass a visual inspection is then connected to a test pump and the • free end is fitted with a quick-opening valve. • 9. Elevate the free end and fill the hose with water from the pump. • Always use water. Never test with flammable or corrosive fluids, solvents or • compressed gas. • 10. As the hose fills with water, bleed the air out through the open valve. Close the • valve and lower it to the ground when all the air is out. • 11. RMA has testing literature available for each hose type. It is imperative to pressure • test the hose at the proper pressure. • 12. Drain the hose and allow it to dry before returning it to service.
1/7/2017 NAARSO 119
• 3. Inspect hose tube for hardness, color • change, cracks, blisters, erosion, etc.
1/7/2017 NAARSO 120
• Level 2 inspections should be conducted, if possible, during regular equipment shutdown
• or at least every three months even if it means shutting the equipment down for
• the specific purpose of hose inspection
1/7/2017 NAARSO 121
H O S E M A I N T E N A N C E T I P S
• 1. Never exceed the rated working pressure of a hose. • Never allow pressure spikes or surges above the maximum rated
working pressure • of the hose. • Excessive pressure can shorten the life of a hose. • 2. Never run over a hose with equipment or vehicles such as fork
lifts. • Running over a hose can damage the tube, reinforcement, and cover. • A build up of pressure can cause damage at the coupling. • 3. Never pull a hose by its coupling. • Pulling a hose at the coupling can kink the hose and weaken the
coupling bond to • the hose. • When moving a hose always lift the hose and coupling together.
1/7/2017 NAARSO 122
• 4. Never lift a heavy, large-diameter hose by the middle with the ends hanging • down. • The internal reinforcement can be damaged at the middle point. • Support large hose every ten feet with rope saddles or slings. • Use dollies, rollers or derricks when moving large hoses. • 5. Never over-bend a hose to the point of kinking. • Never bend the hose tighter than the recommended bend radius. • Never kink a hose to stop the flow of material. • Kinking a hose can seriously damage the tube and reinforcement. • If needed, install bend restricters at the coupling to prevent the hose from being • bent past the bend radius. • 6. A hose cover exposed to excessive wear can be protected with an extra cover, • such as a nylon sleeve or pad. • Make the cover slightly longer than the hose to accommodate any change in the • hose length when in use. • 7. Remove kinked or crushed hose from service immediately. Inspect and test
the • hose before putting it back in service. • An outside diameter of a hose which has been permanently reduced by more than • 20 percent should be removed from service. • An outside diameter of a hose which has been reduced by 20 percent or less, • should have a hydrostatic test done before being put back into service. See RMA • Hydrostatic Testing Procedures 1/7/2017 NAARSO 123
• 8. Remove and test any hose assembly that is subjected to abuse. • This includes hose that has been severely pulled at the coupling, flattened, • crushed or kinked. • 9. Visually inspect and pressure test hose at regular intervals. • This is extremely important for critical application hoses, such as acid/chemical, • steam, LPG and petroleum. • Check for kinks, bulges, soft spots, loose areas, abrasions and cuts. • Cuts or abrasions which expose the reinforcement are signs that the hose should • immediately be removed from service. • 10. Always check for fluid seepage by pushing down at the base of the coupling • with your thumbs. A hose softened by fluid seepage must be replaced. • Check for coupling slippage. • Remove any hose that does not pass your visual inspection.
1/7/2017 NAARSO 124
1/7/2017 NAARSO 125
1/7/2017 NAARSO 126
1/7/2017 NAARSO 127
1/7/2017 NAARSO 128
1/7/2017 NAARSO 129
1/7/2017 NAARSO 130
1/7/2017 NAARSO 131
1/7/2017 NAARSO 132
1/7/2017 NAARSO 133
1/7/2017 NAARSO 134