This document analyzes and synthesizes the hydraulic system of a deep injection machine. It describes the existing system and identifies problems with it, such as hydraulic shocks caused by parallel valves. A new synthesized system is proposed with advantages like increased productivity and simplified structure. The document also discusses the need for filtration of the system's water work fluid due to contaminants. It proposes pressure characteristic testing methods to identify defective hydraulic devices without dismantling the system. This allows for timely repairs and reduces failure analysis costs.

1. ANALYSIS AND SYNTHESIS
OF THE DRIVE HYDRAULIC SYSTEM FOR
THE DEEP INJECTION MACHINE
M.Sc. Nikola Stanchev, Ph.D student
TECHNICAL UNIVERSITY OF SOFIA
Department of Hydroaerodynamics and Hydraulic Machines

2. GENERALLY REPRESENT, TECHNICAL DATA
 An analysis and synthesis of consideration hydraulic system is based on a specialized
unit to keep pressure in earth layers developed by the company "Gidronas" AD as an
alternative to manufactured piston, centrifugal and screw pumps, used for such
purposes, namely:
- Use one or more modules in parallel to transfer layer liquid or oil to the settling
tanks or storage;
- To maintain the pressure in the layers through reinjection
into the oil- bearing layer of liquid waste;
Specifications:
Capacity: 40-110, m³ / 24h;
Rated output pressure: 10 to 15, MPa;
Nominal inlet pressure: 0,4, MPa;
Efficiency: 70%;

3. DESCRIPTION OF EXISTING SOLUTION
M
15 kW
1450 rpm
C
P
SF
CV
PRV
28 cc
200 bar
M
15 kW
1450 rpm
C
P
SF
CV
28 cc
B
H2O
p
i
q ≈ 40 l/minq ≈ 40 l/min
A2M1 M2
WCV1
WCV2
WCV3
WCV4
PS1
q ≈ 160 l/min
pmax = 4 bar
A1
PF
L
a5 a6 a7 a8
a1 a2 a3 a4
M
WP
CO
CGS2S1
VA1 VA4
VA2 VA3
Operating unit
Drive unit

4. ANALISYS OF EXISTING SOLUTION
 Under the work condition of the existing system and technical analysis of the decision
were identified the following problems and shortcomings:
- the function of combination of four valve groups, presence of hydraulic shocks
in the system due to parallel work of the separate valves;
- well configured system does not allow for quick and accurate
failure detection and location of faulty element occurrence
This reflects on usability and on
the allowable lifetime of the machine.
?

5. SYNTHESYS OF NEW HYDRAULIC SYSYEM
200 bar
M
15 kW
1450 rpm
C
P
SF
CV
PRV
M1
28 cc
200 bar
M
15 kW
1450 rpm
C
P
SF
CV
28 cc
PRV
M2
B
p
i
q ≈ 40 l/minq ≈ 40 l/min
A2M3 M4
WCV1
WCV2
WCV3
WCV4
PS1
q ≈ 160 l/min
pmax = 4 bar
A1
PCV1 PCV2
Pilot ratio
1:3,5
Pilot ratio
1:3,5
p
i i
p
PS2 PS3
P T
A B
a1 b1
DV WP
PF
L
H2O
M
CO
CG
S1 S1

6. ADVANTAGES OF THE NEW HYDRAULIC SYSYEM
200 bar
M
15 kW
1450 rpm
C
P
SF
CV
PRV
M1
28 cc
200 bar
M
15 kW
1450 rpm
C
P
SF
CV
28 cc
PRV
M2
B
p
i
q ≈ 40 l/minq ≈ 40 l/min
A2M3 M4
WCV1
WCV2
WCV3
WCV4
PS1
q ≈ 160 l/min
pmax = 4 bar
A1
PCV1 PCV2
Pilot ratio
1:3,5
Pilot ratio
1:3,5
p
i i
p
PS2 PS3
P T
A B
a1 b1
DV WP
PF
L
H2O
M
CO
CG
S1 S1
2 PRV+
2 CV = [p]
Only one directional
element, simplifying
of the system, alsoo ↓
the risk of damages
PCV = ↑q > ↓T for
filling and empting of
the accumulators >
increased productivity
Damping

7. NEED OF DEFECTATION FOR WORKING CIRCUIT OF THE SYSTEM
 Defectation is necessary by the fact that the work fluid in the work unit is water with
strong presence of contaminations, which influence of the correctly functioning of the
system
 For this reason is proposed methodic for correct defectation of the main components
from the work unit - the valve devices WCV. The main damage occurred on hermetic
sealed surfaces of the valve and on the leading (guiding) surfaces, which violates their
proper function.

8. SOLUTIONS FOR DEFECTATION - WORKING CIRCUIT OF THE
SYSTEM
p, bar
t, s0
180 ►
▲
a1
PS1
▲
b1
4 ►
p, bar
t, s0
180 ►
▲
a1
▲
b1
4 ►
▲
a1
p, theoretical
p, actual
▲
a1
PS1
Solenoid:
Solenoid:
Pressure characteristics, normal operation

9. SOLUTIONS FOR DEFECTATION - WORKING CIRCUIT OF THE
SYSTEM
p, bar
0
180 ►
▲
a1
PS3
▲
b1
4 ►
p, bar
0
180 ►
▲
a1
PS1
▲
b1
4 ►
▲
a1
p, theoretical
p, actual
▲
b1
▲
a1
▲
b1
Non hermetic WCV2 Non hermetic WCV1
Non hermetic WCV3 Non hermetic WCV3, 4
Solenoid:
Solenoid:
Pressure characteristics, damage!

10.  Functionality of the system is achieved in order to best match the existing
requirements, significantly simplifying the structural performance;
 Relative relieved failure analysis with defining the damage
occurred, both in quality and in size;
 Timely and accurate identification of defective
hydraulic devices, without need for dismantling the system;
 According to the pressure characteristics is possible
to determine when and how to carry out repairs
or replacement of the devices works;
All shown above reduces multiple the cost of failure
analysis and timing of repairs.
CONCLUSIONS

11. THANK YOU
FOR ATTENTION!
TU - Sofia, Department: HAD and HM

12. TU - Sofia, Department: HAD and HM
ANY
QUESTIONS!?