Ass. 2
Ass. 2
Ass. 2
Assignment No. : ( 2 )
Assessor Name : Dr. Shehab
Internal verifier Name : Dr. Sherif Al Hosary
When the outlet flow is resisted, pressure in the pump outlet chamber builds up rapidly and forces the
gear diagonally outward against the pump inlet. When the system pressure increases, imbalance occurs.
This imbalance increases mechanical friction and the bearing load of the two gears. Hence, the gear
pumps are operated to the maximum pressure rating stated by the manufacturer.
It is important to note that the inlet is at the point of separation and the outlet at the point of mesh.
These units are not reversible if the internal bleeds for the bearings are to be drilled to both the inlet
and outlet sides. So that the manufacturer’s literature should be checked before attempting a reversed
installation. If they are not drilled in this manner, the bearing may be permanently damaged as a result
of inadequate lubrications.
External gear pumps are the most popular hydraulic pumps in low-pressure ranges due to their long
operating life, high efficiency and low cost. They are generally used in a simple machine. Gear pump
provides smooth pumping action & high volumetric efficiency. It is used in industrial machine for a fluid
delivery and for a cooling purpose. It is used with a wide range of fluid viscosity.
External gear pumps are less expensive but limited to pressures below 140 bar. It is noisy in operation
than either vane or piston pumps. Gear pumps are invariably of fixed displacement type, which means
that the amount of fluid displaced for each revolution of the drive shaft is theoretically constant.
Advantages and disadvantages of external gear pumps :
When looking for a device to move load in both directions, double acting cylinders are a useful
application when your machine requires more than one movement. Unlike single acting air cylinders,
double acting cylinders can extend and retract without the need of a spring. Instead of applying
pressurized air into one port, double acting cylinders have two ports where air can enter in and out.
Air enters through one port moving the piston forward and then applies pressurized air into the other
port retracting the piston back into the cylinder. Double acting cylinders are the most widely used
pneumatic actuators compared to single acting cylinders given their ability to extend and retract within
a shorter time period, thus, becoming more efficient and precise.
Double acting pneumatic cylinders are mostly used in industrial and robotics industries. They perform
tasks such as opening/closing doors and lifting and moving merchandise off conveyor belts. Other uses
include medical applications, earth-moving equipment and space programs.
• More control over movement since pressurized air moves both ways
• Many double acting pneumatic cylinders are ISO compliant as opposed to single pneumatic
cylinders
• Requires bigger housing - if used as a feed cylinder it needs to be coupled with another machine
system
• Pressure transmitters provide absolute, gauge, or differential analog readings over wide
measuring ranges
Task 3
Q1) :
Health and safety rules for hydraulic systems :
Installation safety :
• Before disconnecting oil lines, relieve all hydraulic pressure and discharge the
accumulator (if used).
• Be sure all line connections are tight and lines are not damaged; escaping oil under
pressure is a fire hazard and can cause personal injury.
• Some hydraulic pumps and control valves are heavy. Before removing them, provide a
means of support such as a chain hoist, floor jack or blocks.
• When washing parts, use a nonvolatile cleaning solvent.
• To ensure control of the unit, keep the hydraulics in proper adjustment.
Operation safety :
An improperly maintained hydraulic system can lead to component failures. Safe hydraulic
system performance requires general maintenance.
• Periodically check for oil leaks and worn hoses.
• Keep contaminants from hydraulic oil and replace filters periodically.
• Coat cylinder rods with protective lubricants to avoid rusting.
Health and safety rules for Pneumatic systems :
1- Always make sure you have a precise circuit as well as the pneumatic system's
functional diagram. Make sure that any adjustments made following installation are also
made in the instructions.
2- Make sure the system's impulse valves are shielded from excessive dirt, mechanical
shocks, and cooling water.
3- The elements' and the units' imprints should be precise and obvious.
4- Only use the valve openings specified by the manufacturer.
5- A new opening shouldn't be made by drilling the system's components.
6- Discuss your needs with the manufacturer if you require an additional opening; they
may come up with a special system just for you.
7- The system's service unit needs to be easily accessible and visible. Make sure it is
positioned higher than the other elements, if at all possible.
8- Only increase the throttle as directed by the manufacturer.
9- If you're disassembling cylinders or valves, be careful with the sealing materials. Make
sure they are positioned correctly even when reassembling them.
10- Actuated valves might seem simple to use, but they have a history of causing major
issues. Therefore, it is wise to make sure they are only controlled in the proper
directions and at the necessary speeds.
For the purpose of removing heat and other harmful contaminants, it is imperative to
regularly maintain a variety of conditioning devices, such as coolers, filters, dryers, and
lubricators. Cleaning, visual inspection, running checks, and servicing of filters, lubricators,
and coolers are the typical routine maintenance procedures. Any unusual noises in the
system should be looked into as soon as possible.
• Plugging Leaks
An essential requirement of any pneumatic system is to stop leakage, as expensive leaks
cost big money. Application of soapy water or commercially available leak detecting liquids,
like aerosol sprays, on suspected joints, might reveal the presence of leaks. An ultrasonic
leak detection instrument can also be used to locate leakages.
• Mounting of Components / Machines
The mounting bolts of components must be torqued correctly. Further, every prime mover
must be perfectly aligned with the associated load part to reduce undue stress on
components, seals, and bearings. A maintenance technician should check for any vibration,
loose bolts, or misalignment of components in a system.
Q2) :
Error: Over load System overloading either halts operations or slows down processes. See
Pregnancy Specs Guide.
Precaution: Do not connect low pressure components to high pressure systems. Mismatched
components can burst hoses or fittings. Never use your hands to find leaks in hydraulic lines. This
is because the hydraulic fluid (often oil) is under high pressure.
Error: It is possible for the system to behave inadvertently while maintaining processes.
Precaution: Disconnect the system from power.
Error: Aeration/Cavitation: The presence of air bubbles reduces performance.
Precaution: Relieve drive system hydraulic pressure before removing or changing components.
Error: no oil in system.
Precaution: Check for leaks. Eye protection and gloves should be worn when looking for leaks.
Error: Low viscosity: Low viscosity liquids cause leakage problems.
Precaution: Replace the fluid with any of the required viscosities.
Q3) :
1- Air compressor
Air Compressor Preventive Maintenance Checks
Checking Compressor Pump Oil Level
Unless your air compressor is an oil free compressor, do not operate without lubricant or with
inadequate lubricant. Manufacturers and the company from whom you bought it from cannot
be responsible for failure due to inadequate lubrication.
1. Ensure unit is off and disconnect from the power source
2. Ensure compressor is on a flat and level surface
3. Remove fill cap / plug
4. Inspect the oil in the crankcase assembly and look for dirt or debris
5. Oil should not exceed the halfway point of the sight glass
Changing Compressor Pump Oil
Remember, the compressor pump heads and surrounding parts are HOT!
1. Ensure unit is off and disconnect from the power source
2. Ensure compressor is on a flat and level surface
3. Remove fill cap / plug
4. Place collection container underneath the oil drain cap.
5. Remove the oil drain cap, and let the oil drain out.
6. Replace the oil cap and be sure to tighten this nut securely. White plumbers’ tape (PTFE)
is generally a good idea to help create a tighter seal. Fill crankcase with appropriate oil,
be sure it does not exceed the halfway point.
Checking the air filer element
For the more common reciprocating air compressors.
1. Ensure unit is off and disconnect from the power source
2. Allow compressor pump to cool off.
3. Unscrew the filter top from the filter base by turning (generally) counter-clockwise.
4. Separate the filter top cover from the base.
5. Remove the element from the filter base
6. Blow out dust and debris from the filter element.
7. Replace element if needed.
8. Reconnect filter top to the base and secure filter.
Checking the air filer element
For the more common reciprocating air compressors.
1. Ensure unit is off and disconnect from the power source
2. Allow compressor pump to cool off.
3. Unscrew the filter top from the filter base by turning
Troubleshooting methods
2- Double acting cylinder
Double acting cylinder maintenance
Regular inspections. Check whether the rod has any pitting, corrosion or uneven wear. Uneven wear
could signal an impending disaster for the entire hydraulic system. Corrosion may indicate too much
moisture either in the fluid itself or ambient moisture. It could also speed up wear on seals. Pitting can
also lead to seal damage and can occur as a result of corrosion. There is plenty to watch for.
If you find that there is uneven wear on your rod, it is most likely caused by misalignment. If there is a
load on one side only, it’s going to accelerate the wearing of the seals, bearing and of course, the rod
itself. In almost all cases it’s possible to polish or re-chrome a rod that’s been damaged. If it’s not
possible to refinish it to repair it, then a new one can be manufactured by a cylinder repair shop. Prior to
reinstalling, check that the causal problem has been remedied, or you’ll find yourself needing to pass
through the same process.
Cylinder rotation. If it’s critical that there is no downtime, keep a full set of cylinder spares that can be
rotated regularly. You will retain fresh cylinders, even though you will be a high risk of particle
contamination. When a cylinder is removed from service, inspect it and give it maintenance as required.
Once dissembled, replace seals as they are normally very affordable. You can then look for clues on how
the rest of your hydraulic circuit is by inspecting the inside the cylinder interior. Look for varnish, and if
you find it you know that your oil is running too hot and may need to be addressed.
A visual inspection of the piston and cap will give you an idea of whether the cylinder has trapped
particles. If it’s pitted like somebody has been attacking it with an ice pick, then there’s no doubt that a
piece of metal has been banging around in there for some time. If it’s reached your cylinder, then it’s
already been elsewhere in the system.
Check lube oil system. If you have pneumatic cylinders, there is a need for a source of lubrication. Check
whether there is enough oil in the associated reservoir. You may have a full reservoir of oil, but that
doesn’t guarantee that the system is working. You may need to hook up a blow gun and a white paper
towel to check. If you find oil is being squirted onto the towel, all is good. If not, then you may have a
clog to sort out, or a lubricator to replace.
Not a large amount of oil needs to be introduced as a lube otherwise it can interfere with operations. A
fine mist is enough to keep things moving.
Accessory service. In addition to the hydraulic cylinder being very important to service, pay attention to
rod eyes, clevises, brackets and ball joints. Ensure that there is no major play in the cylinder joints from
a worn clevis or pivot pin.
Keep oil clean. It’s an obvious point but still has to be made. Most hydraulic failures are caused by
contaminated oil. Filter your oil! All those dirt particles like moving up and down inside a cylinder, so
ensure that it’s clean as soon as it enters a cylinder for a first time.
Hydraulic cylinder troubleshooting
1. Your Cylinder Makes Banging or Knocking Sounds
Hydraulic cylinders make some noise — however, these sounds shouldn't be alarming.
Sometimes, a fault in a cylinder causes loud banging or knocking sounds. You often hear these
noises when the cylinder has a cavitation problem. There might not be enough fluid in the
cylinder to enable it to run smoothly. Alternatively, you might have an aeration problem, in
which your fluid levels might be adequate, but you have too much air in your system. Cavitation
or aeration problems create unusual pressure differentials in your cylinder. Any air bubbles in
the system will then react to these pressure fluctuations by imploding and exploding. When this
happens, you hear loud banging or knocking sounds.
2. Your Cylinder Moves Differently
Hydraulic cylinders should work smoothly. However, sometimes a problem cylinder will start to
make jerking or juddering movements. This is a sign that the cylinder's piston and rod can't
move freely or smoothly. These jerking movements often result from too much friction in the
system. For example, you might have problems with worn or damaged seals or parts.
Alternatively, you might not have enough lubrication running through the cylinder to keep it
running smoothly.
3. Your Cylinder Is Too Hot
Hydraulic cylinders have set temperature ranges. They shouldn't heat up past a certain point.
You know you have a problem if your cylinder feels hotter than it usually does. Sometimes this
temperature increase is part of a bigger problem. For example, if a cylinder has juddering
movements, then it will also probably start to heat up more because of the underlying friction
problem. However, excess temperature can also be a stand-alone problem or early warning sign
of a potential breakdown. They can come down to problems with your hydraulic fluid or its
levels. On the other hand, you might have a faulty oil filter.
4. Your Cylinder Runs Slow
A faulty hydraulic cylinder sometimes loses some power. It might seem to work more slowly
than it should. It then affects its machine's operating speed and power. You'll notice that the
machine cycle takes longer than usual. Sometimes a cylinder slows down because of internal
friction. However, this problem is more often caused by flow glitches. If the cylinder's flow is
too low, then the system's actuator can't work to optimum efficiency. A slow cylinder might
indicate that you have a leak that affects internal pressure. You might see signs of an external
leak around the cylinder, say, if a hose breaks. However, internal leaks aren't visible. Either kind
of leak will slow down the cylinder because it has to work harder to create the right pressure
levels. This takes more time, so the cylinder works more slowly.
5. Your Cylinder Uses More Power
If you notice that your machine is using more power, then you could have a cylinder problem. If
your cylinder has to work harder to do its job, then it needs more energy to work. Too much
friction or a leak in the cylinder can cause this problem. For example, if you have a leak, then
the cylinder has to pump through more fluid to compensate. This makes the cylinder work
harder and longer.
Operation
The hydraulic system operates under the Pascal's Pneumatics employs an air compressor to reduce
law principle, which states that the pressure in an air volume and raise air pressure. Once in
enclosed fluid is constant in all directions. A pump is pneumatic tubing, it travels via a filter and is
controlled by valves before arriving at an
used in hydraulic systems to move hydraulic fluid
actuator, which concludes the process. An
through the system and provide fluid power. The ongoing supply of compressed air from a storage
cylinder is where the fluid enters after passing tank is necessary for pneumatic systems. To
through the valves and is transformed back into provide this, an air compressor is employed. Air is
mechanical energy. The valves support controlling taken from the atmosphere by the compressor
liquid flow and releasing pressure when required. and stored in a high-pressure air reservoir. A
network of pipelines and valves is then used to
deliver compressed air to the system.
legislation
PSSR (Pressure Systems Safety Regulations) The safe Pressure Systems Safety Regulations 2000 (S.I.
design and usage of pressure systems are covered by 1999/2024). Anyone who creates, produces,
the Pressure Systems Safety Regulations 2000 (PSSR). imports, or distributes a pneumatic system
Its goal is to stop serious injury caused by pressure
that is meant to be a component part of a
hazards that could occur if a pressure system or one of
its components fails. 2. Hydraulic Fluid Power — pressure system must make sure that it is
General Rules and Safety Criteria for Systems and Their correctly designed, properly constructed, and
Components (ISO4413:2010) deals with all significant made of a material that is suitable for
and establishes general rules and safety requirements pressure systems. Additionally, the pressure
for hydraulic fluid power systems and components used system must be equipped with sufficient
on machines. The risks associated with hydraulic fluid protection mechanisms to avoid danger. 2.
power systems are outlined, along with the precautions
The Pressure Equipment Regulations of 1999
that should be taken to avoid them while using the
systems as intended. (SI1999/2001) (PER) 3. The SPV (Simple
Pressure Vessels (Safety) Regulations)