The pressure energy is fed to the actuator through a number of control block called valves.
• Various type of valve are used in hydraulic system to control or regulate the flow medium.
• Basicallyvalvesareexpectedtocontrol: – Direction
– Pressure
– Flow
– Otherspecialfunctions.
Hydraulic Systems are very delicate systems, if contamination enters the systems failure will occur in the form of partial functional failure or total functional failure.
Training, education, and standardization is the only path to success. It is all about the "Failure Modes" and their causes.
This short assortment of slides provides recommended actions to solve these problems at the end.
Good Luck and God Speed.
The pressure energy is fed to the actuator through a number of control block called valves.
• Various type of valve are used in hydraulic system to control or regulate the flow medium.
• Basicallyvalvesareexpectedtocontrol: – Direction
– Pressure
– Flow
– Otherspecialfunctions.
Hydraulic Systems are very delicate systems, if contamination enters the systems failure will occur in the form of partial functional failure or total functional failure.
Training, education, and standardization is the only path to success. It is all about the "Failure Modes" and their causes.
This short assortment of slides provides recommended actions to solve these problems at the end.
Good Luck and God Speed.
Hydraulic Valves and Hydraulic System AccessoriesRAHUL THAKER
Hydraulic Valves and Hydraulic System Accessories:
Direction control valves,Pressure control valves, Flow control valves, Non-return valves, Reservoirs,Accumulators, Heating & cooling devices, Hoses. Selection of valves for circuits.
Following presentation consist of a fundamental steps that took place during a pump overhaul.
this presentation will give you the basic idea about maintenance .
Hydraulic Filters are used to keep the contaminants away from the system and avoid mechanical failures. Fleetguard products cater to high, low and medium pressure hydraulic systems to protect industrial machinery and equipments.
For more details visit: https://www.fleetguard-filtrum.com/products/hydraulic-filtration/
HYDRAULIC POWER GENERATING AND UTILIZING SYSTEMS
Introduction to fluid power system - Hydraulic fluids - functions, types, properties, selection and application.
POWER GENERATING ELEMENTS: Pumps, classification, working of different pumps such as Gear, Vane, Piston (axial and radial), pump performance or characteristics, pump selection factors- simple Problems.
POWER UTILIZING ELEMENTS: Fluid Power Actuators: Linear hydraulic actuators – Types and construction of hydraulic cylinders – Single acting, Double acting, special cylinders like tandem, Rodless, Telescopic, Cushioning mechanism.
Hydraulic Motors, types – Gear, Vane, Piston (axial and radial) – performance of motors.
Electro hydraulic system Components and their operationSrichandan Subudhi
After this presentation you will be knowing:
1.What are DCVs, its type and their uses
2.About Check Valves and pilot controlled check valves
3.What are solenoid actuated valves and their operation
4.What are proportional solenoid valves and their operation
5.Servo Valve Operation
6.Servo Valve Connector
In hydraulic and pneumatic systems flow control valves are necessary to vary the speed of actuator. Flow control valves are placed in between Actuator and Direction Control (DC) Valve
Control of a single-acting and double-acting cylinder, regeneration, motor braking, speed control, synchronisation, fail safe, two handed, application of counterbalance, sequence, unloading, pressure reducing, pilot operated check valve
Most companies spend a lot of money training their maintenance personnel to troubleshoot a hydraulic system. If we focused on preventing system failure then we could spend less time and money on troubleshooting a hydraulic system.
If you are experiencing hydraulic problems then this article is a must to read because it is based on "known best practices"? Think about it.
Hydraulic Valves and Hydraulic System AccessoriesRAHUL THAKER
Hydraulic Valves and Hydraulic System Accessories:
Direction control valves,Pressure control valves, Flow control valves, Non-return valves, Reservoirs,Accumulators, Heating & cooling devices, Hoses. Selection of valves for circuits.
Following presentation consist of a fundamental steps that took place during a pump overhaul.
this presentation will give you the basic idea about maintenance .
Hydraulic Filters are used to keep the contaminants away from the system and avoid mechanical failures. Fleetguard products cater to high, low and medium pressure hydraulic systems to protect industrial machinery and equipments.
For more details visit: https://www.fleetguard-filtrum.com/products/hydraulic-filtration/
HYDRAULIC POWER GENERATING AND UTILIZING SYSTEMS
Introduction to fluid power system - Hydraulic fluids - functions, types, properties, selection and application.
POWER GENERATING ELEMENTS: Pumps, classification, working of different pumps such as Gear, Vane, Piston (axial and radial), pump performance or characteristics, pump selection factors- simple Problems.
POWER UTILIZING ELEMENTS: Fluid Power Actuators: Linear hydraulic actuators – Types and construction of hydraulic cylinders – Single acting, Double acting, special cylinders like tandem, Rodless, Telescopic, Cushioning mechanism.
Hydraulic Motors, types – Gear, Vane, Piston (axial and radial) – performance of motors.
Electro hydraulic system Components and their operationSrichandan Subudhi
After this presentation you will be knowing:
1.What are DCVs, its type and their uses
2.About Check Valves and pilot controlled check valves
3.What are solenoid actuated valves and their operation
4.What are proportional solenoid valves and their operation
5.Servo Valve Operation
6.Servo Valve Connector
In hydraulic and pneumatic systems flow control valves are necessary to vary the speed of actuator. Flow control valves are placed in between Actuator and Direction Control (DC) Valve
Control of a single-acting and double-acting cylinder, regeneration, motor braking, speed control, synchronisation, fail safe, two handed, application of counterbalance, sequence, unloading, pressure reducing, pilot operated check valve
Most companies spend a lot of money training their maintenance personnel to troubleshoot a hydraulic system. If we focused on preventing system failure then we could spend less time and money on troubleshooting a hydraulic system.
If you are experiencing hydraulic problems then this article is a must to read because it is based on "known best practices"? Think about it.
Repeatable, effective maintenance procedures are seen as “not required” however this couldn’t from the truth. Over my career I have seen thousands of examples of human variation creating equipment failure at the wrong time. We as humans are built to produce variation in almost everything we do. Most people deny this human variation exist however when I ask a manager if they ever could not find their car keys they look at me sheepishly and say “yes, great point”.
Many companies honestly believe there maintenance staff are paid to “know how to do it” without a procedure with specifications, step by step instructions, etc. What if a maintenance employee does “know how to do it” every-time? One must take into consideration their skill level, current state mind, and current working condition, in order to mitigate human error. In addition, what would happen if new information presents itself based on failure data? The only way to insure this new information is used effectively would be to write or change a procedure.
Well-designed maintenance procedures will mitigate human induced failures and allow for continuous improvement to occur naturally.
Hydraulic hoses exist on nearly every hydraulic machine. It is critical to ensure hose assemblies are fabricated with care to ensure reliability of the hose and the hydraulic system they’re part of.
This presentation covers the essentials of hydraulic hose assembly to ensure the machine is safe and dependable.
Watch the webinar: http://www.fluidpowerworld.com/webinar-proper-hose-assembly-guidelines/
• Cooperated with fellow colleagues in a lab environment and experimented on the science of fluid flow through various types of piping and fittings.
• Researched the head loss that is caused in different piping including Venturi pipe, orifice plate, and elbow pipe fittings.
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Best Practices for Mobile Hydraulic DesignDesign World
With ever-rising fuel prices, designing efficient hydraulic systems can pay big dividends for users of mobile hydraulic vehicles. Join Design World as we take an in-depth look at three critical areas of mobile hydraulic system design: filtration, sensors and sealing. Our expert panel presents critical design tips and answering your questions.
Attendees will learn:
* How to use in-cylinder position sensing to optimize hydraulic functions on mobile equipment
* How to select the appropriate filtration grade for a specific application
* How do shaft requirements impact mobile hydraulic sealing products
The panel includes: Dr. Christian Bauer, Staff Scientist, Pall Corp.; Haubold “Hub” vom Berg, Technical Marketing Manager, MTS Sensors, Mobile Hydraulic; and Joel Johnson, VP of Technology, Simrit. The panel is moderated by Design World Editorial Director, Paul J. Heney.
It is free checklist for solenoid valve troubleshooting, they list most problem of solenoid valve you might encounter, and some solution to solve the problems.
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Being a sophisticated device, when Pressure Reducing Valve (PRV) is subjected to the harsh working conditions, there could be chances of choking up of the valve which eventually leads to disruption in the outlet pressure, noise, vibration and inadequate flow. Downtime goes up along with the maintenance cost. This presentation talks about common issues, the root cause analysis and troubleshooting the same.
Discover cost-saving new products, technologies & ideas for precise machine control at the Drive for Technology!
Drive for Technology Expo is the must-see technology event of the year. Attend your choice of in-depth seminars by industry leaders on the latest in electro-mechanical, hydraulic and pneumatic technologies. Walk the trade show for demonstrations from 25+ of the top suppliers in the areas of motion control, hydraulics, electric, power transmission and linear systems.
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Sr Director, Infrastructure Ecosystem, Arm.
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Bob Boule
Robert Boule is a technology enthusiast with PASSION for technology and making things work along with a knack for helping others understand how things work. He comes with around 20 years of solution engineering experience in application security, software continuous delivery, and SaaS platforms. He is known for his dynamic presentations in CI/CD and application security integrated in software delivery lifecycle.
Gopinath Rebala
Gopinath Rebala is the CTO of OpsMx, where he has overall responsibility for the machine learning and data processing architectures for Secure Software Delivery. Gopi also has a strong connection with our customers, leading design and architecture for strategic implementations. Gopi is a frequent speaker and well-known leader in continuous delivery and integrating security into software delivery.
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Create a campaign using Mailchimp with merge tags/fields
Send an interactive Slack channel message (using buttons)
Have the message received by managers and peers along with a test email for review
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In a second workflow supporting the same use case, you’ll see:
Your campaign sent to target colleagues for approval
If the “Approve” button is clicked, a Jira/Zendesk ticket is created for the marketing design team
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- For beginners: discover PowSyBl's functionalities through a quick general presentation and the notebook, without needing any expert coding skills;
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2. Introduction
Introd ction
Welcome to the CMA/Flodyne/Hydradyne’s
Hydraulic Troubleshooting presentation.
We will introduce many aspects of
troubleshooting hydraulic systems and will
share information that will help you to better
understand and enhance the operation of
your hydraulic equipment.
3. Agenda
Mentally Prepare
Documentation
Starting the process
Predictability
System Isolation
Pumps
Overheating
Actuators
Valves
Accumulators
Questions and answers
4. MENTALLY PREPARE
Use Safety Equipment
Apply General Safety Rules
Lockout T
L k t / Tag-out
t
Work with a pa e
o partner
Be Afraid of Hydraulic accumulators
Have Complete Documentation
5. Obtain Documentation and
Determine a Direction
Obtain ll H d li
Obt i all Hydraulic and El t i l
d Electrical
Schematics pertaining to the equipment
Manuals on the machines operation
Determine your starting point based on the
symptoms.
symptoms
6. Starting the Process
g
Understand the machine sequence and operation
What is the machine doing or not doing?
Intermittent or continuous
I t itt t ti
Smell, feel, listen, touch and see
Machine running slow or fast
Pressure low or high
Shock, banging, vibration
7. Predictability
Expect a result – Be predictive
Every ti
E time an adjustment i made predict what should h
dj t t is d di t h t h ld happen.
Every time you shift a valve predict what will happen.
If your predication is correct continue troubleshooting.
If your predication IS NOT correct find out why.
Do t
D not make a change j t t see what will happen.
k h just to h t ill h
You must make a predication especially when working with
a partner!
8. Isolating Portions of the System
Isolating portions of the circuit is a good way to identify the area of concern
concern.
Lacking pressure? - Try to isolate the hydraulic system from the
rest of the system by blocking the pressure source (close a ball
source.
valve, disconnect a line and plug, etc…)
Lacking flow – The flow is taking the path of least resistance.
(Isolate portions of the circuit, check all ball valves/safety valves,
listen to relief valves, feel for heat, etc..)
10. Flow and P
Fl d Pressure
Hydraulic pumps create flow not pressure
Resistance to flow creates pressure
Flow determines actuator speed
Pressure determines actuator force
Fluid ill l
Fl id will always t k th path of l
take the th f least t
resistance.
When Fluid moves from an area of high
pressure to an area of low pressure ( pressure drop)
without performing work, heat is generated.
11. Symptom: Noisy Pump
Cavitation? (pump starving for fluid) Damaged pump?
Reasons/Possible solutions might be:
Inlet Strainer clogged –Remove or replace inlet strainer
Examine inlet pipe for any obstructions
Examine inlet pipe to ensure that the connections are tight and that the proper
sealant/o rings
sealant/o-rings were used at all connections If air is being drawn into the pump
connections.
through these points, the pump will cavitate. Repair loose connection with
proper sealant, or replace damaged inlet line.
Wrong fluid being used – viscosity too high or operating temperatures are too
low, thus causing the viscosity to increase.
, g y
Excessive drive speed
Reservoir design incorrect with no baffles, too shallow, or oil level too low, thus
causing a vortex in the reservoir and inducing air into the pump inlet.
Plugged or dirty filler breather element on reservoir
Worn or damaged shaft seal on pump. (Check shaft for misalignment)
Aeration of fluid in the reservoir (return lines above the oil level)
Contamination or high heat (monitor ISO cleanliness codes and temps)
12. Symptom: Noisy Pump
Fixed displacement or Pressure compensated
Normal wear
If pump is fixed displacement, it may be:
p p p , y
Worn or sticking vanes
Worn ring
Worn or faulty bearings
y g
Worn or damaged gears
If pump is pressure compensated, it may:
Have worn Internal parts (Vanes, rotary group, bearings, causing internal leakage)
If your pump has a case drain line, a quick check for inefficiency is to remove
the case drain line and drop it into a bucket. While the pump is in
compensation, monitor how much fluid is coming from the case drain line. It
p , g
should be within the catalog characteristics. If more than 10% of the pumps
maximum output is going over the case, this would indicate that the pump
requires rebuild or replacement.
Inefficiencies or internal leakage will show signs of high heat. Temperature
g g g p
readings at the pump during a morning start-up will help to identify the source of
the heat and determine leakage/inefficiencies, thus indicating pump replacement
13. System Overheating?
Determine the source
What is too hot?
Is the pump overheating?
I a valve or actuator overheating?
Is l t t h ti ?
General overheating
14. Symptom: Over heating of system
y p g y
What is the maximum temperature for a hydraulic system?
For safety, efficiency, and oil quality, temperatures above 140 degrees F are not
recommended for industrial hydraulic equipment.
Oil th t i t h t will degrade rapidly, drop in viscosity, and can lead to accelerated
that is too hot ill d d idl d i i it d l dt l t d
component wear and poor system performance. A broken hose or leak in a line can
seriously burn someone.
Causes of overheating systems:
C f h ti t
Contamination causing wear of components, thus creating internal leakage of the
component and higher operating temperatures.
Relief valve misadjusted
misadjusted.
Compensator on pump may be set higher than the relief valve in the system
Flow control valves may be set improperly.
Water supply feeding heat exchanger may be shut-off or has insufficient flow or
temperature for cooling
cooling.
Heat exchanger may be clogged or water modulating valve may have failed.
If an air to oil heat exchanger is in the system the cooling fins may need to be cleaned,
or electric motor, or starter may have failed.
Ambient air temperature may have increased and can no longer supply sufficient cooling
p y g pp y g
media. Inadequate ventilation or area of room size may have changed.
Incorrect fluid used in hydraulic system
Defective pump ( See Noisy pump)
15. Actuators not functioning?
Cylinders
1. Speed
p
2. No Movement
3. Insufficient force
Hydraulic motors
1. Speed
2. No Movement
3. Insufficient torque
16. Symptom: Actuator fails to move
y p
Reasons and possible solutions:
Note: Usually, when an actuator doesn’t move, the problem is not the actuator.
Directional valve not shifting.
Electrical failure, bad solenoid, limit switch, PLC ect...
Insufficient pilot pressure (If dual stage valve, check pilot and drain
configuration) especially if valve h j t b
fi ti ) i ll l has just been replaced.
l d
Look at any check valves or back pressure valves required to provide pilot
pressure.
System operating pressure to low (see low or erratic pressure)
A valve elsewhere in the system is allowing flow to be diverted to the reservoir
Interlock device not actuated
Mechanical bind on machine or actuator (improper mounting of actuator)
Faulty pump
High heat – viscosity too low
Previous contamination damage/high heat has caused component fatigue,
wear,
wear and failure
failure.
Worn/damaged actuator (cylinder or hydraulic motor blow-by or internal
leakage.
17. Suggestions:
If you think that it may be internal leakage:
Take temperature readings on the system and on both sides of actuator
actuator.
Actuator may be bypassing internally due to worn seals, geroter, gears vanes,
ect…
Extend cylinder fully and disconnect rod end port connection If fluid is
connection.
continuing to flow from rod end port, the cylinder has internal leakage and
requires rebuild or replacement. If no leakage is present, connect the line,
retract the cylinder and remove cap end connection to check for same on
opposite end.
pp
Note: Depending on the seal design, It is possible for a cylinder to leak in one
direction and not the other. A cylinder that leaks internally typically will drift in
t e e te d direction,
the extend d ect o , because o t e a ea d e e ces o t e p sto , e e when
of the area differences on the piston, even e
mounted vertically rod up.
If you experience this type of drifting, the issue is probably the actuator, and you
should start your troubleshooting here.
18. Valves not f
V l t functioning?
ti i ?
Pressure Controls
Directional Controls
Flow Controls
19. Symptoms: Low or Erratic Pressure
y
Reasons and possible solutions:
Pressure control setting too low (
g (relief, compensator, reducing valve,
p g
ect..)
Contaminates in fluid or high heat/low viscosity
Worn or sticking relief valve
Dirt/debris stuck and holding a relief or other valve partially open
open.
Suggestions:
Check cleanliness of fluid and act accordingly.
Take temperature readings at the various valves to identify a noticeable
temperature rise (possible internal leakage)
Put your hand on valve to feel or listen for leakage.
If the valve discharges to tank, disconnect the tank line and connect a
hose from the valve, feeding into a bucket. Start system and measure the
leakage.
leakage Act accordingly to repair or replace the valve
20. Symptoms: No pressure!
Reasons and possible solutions:
Unit not running or pump in reverse direction.
Low oil level or no oil
Drive coupling is damaged or disconnected.
disconnected
Full pump volume by-passing through a faulty valve or actuator.
Suction line of pump obstructed or disconnected
A manual valve may be shifted diverting volume to tank or a solenoid valve
y g
may be un-intentionally energized/shifted or not shifted, due to an electrical
problem. PLC?
(Check all possible valves with a volt meter, or manual
over-ride
over ride if available)
Note: Don’t get stuck on hydraulic, as many times the hydraulic problem you
are experiencing may be mechanical or electrical.
p g y
21. Symptoms: Slow or Erratic Feed Rate /Operation
Reasons and possible solutions:
Air or water in the fluid (will typically produce a milky appearance)
Low fluid level
Viscosity of the fluid is too high or temperature is too low
Contamination
Internal leakage through a valve or actuator
Dirt/debris stuck and holding a valve partially open.
Worn/Inefficient pump
Pump drive speed too low
Faulty or dirty flow control or other feed related valve
Mechanical…misalignment-alignment, sticky warped
Mechanical misalignment-alignment sticky, warped, or binding ways bent
ways,
bracket, or other
Suggestions:
Check level, color, quality, and cleanliness of fluid and act accordingly.
Take temperature readings at the pump, pump case, and various valves to
identify a noticeable temperature rise (possible internal leakage)
Put your hand on valve to feel or listen for leakage.
If the valve discharges to tank, disconnect the tank line and connect a hose from
the valve, feeding into a bucket. Start system and measure the leakage. Act
accordingly to repair or replace the valve.
22. Hydraulic or Electrical ?
H d li El t i l
Often an electrical issue will affect the hydraulic operation
operation.
Don’t get focused on a hydraulic problem until you have
also reviewed electrical issues such as:
No or low voltage at a solenoid valve due to: a
defective limit switch, misadjusted limit switch, PLC
output, power supply, transformer, No control power.
What has changed?
A change to the PLC p g
g program?, a limit switch or other
,
electrical component recently replaced?
23. Proportional & Servo valves
and Drivers
Valves may have on board electronics or be controlled by an amplifier or
on-board
motion control device.
Proportional and servo valves are current driven using “Pulse Width
Modulation”
Before troubleshooting a proportional or servo valve obtain
documentation for the valve and control.
Shielded wire is required for the valve to operate without interference
(electrical noise)
Proportional and servo valves are controlled with either a current or
voltage command to the valve or control device.
Often the problem is not the valve but the amplifier, PLC, feedback
p p , ,
device or broken wire.
What has changed? Ask Questions?
24. Accumulators
A l t
Why is the accumulator in the system?
Nitrogen pressure can not be measured
while system is running
Potential to discharge unexpectedly
Use your senses and ASK QUESTIONS !
25. Most I
M t Important Tools
t tT l
Eyes
Ears
Hands
NNose
Use your senses and ASK QUESTIONS !
26. Where to Get More Information
Wh t G tM I f ti
Other training sessions
Books, Trade magazine articles, Internet, etc..
Consulting services, other sources
Call us anytime!
27. This guide cannot cover all details or all variations in equipment
nor can it provide for every possible condition/solution of cause
and effect.
Feel free to contact us should further information be required.
Were always happy to help!