Fluid Power Journal August 2021 by Innovative Designs & Publishing, Inc.

AUGUST 2021

THE OTC ISSUE ‘TALKING’ FILTERS AND FLUID

SMARTEN UP: A DECADE OF INDUSTRY 4.0 MOBILE

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IN THIS ISSUE

AUGUST 2021

VOLUME 28 • ISSUE 8

Features

6 Speaking of Hydraulics: Filters and Fluid that ‘Talk’ Donaldson’s Filter Minder Connect maintains constant system contact for better maintenance scheduling. 8 A Primer on Mobile Fluid Power A look at how it differs from the industrial segment and some of the advantages.

18 Cover Story Smarten Up: Hydraulics and a Decade of Industry 4.0 The impact of IIoT on fluid power is greater than the sum of its parts. 22 Test Your Skills Understanding Supply-Side Air Preparation 24 Offshore Technology Conference OTC is back live in Houston 26 Count On It: Run-Time Monitor Racks Up the Miles In hydraulic systems, it’s the equivalent of a vehicle’s odometer.

24 Publisher’s Note: The information provided in this publication is for informational purposes only. While all efforts have been taken to ensure the technical accuracy of the material enclosed, Fluid Power Journal is not responsible for the availability, accuracy, currency, or reliability of any information, statement, opinion, or advice contained in a third party’s material. Fluid Power Journal will not be liable for any loss or damage caused by reliance on information obtained in this publication.

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AUGUST 2021

N OTA B L E WO R D S

Preparing for Asset Management 4.0 By Mark Barnes, Senior Vice President, Global Business Development, Des-Case Corporation

IN THE AFTERMATH of World War II, British Prime Minister Winston Churchill famously stated, “never let a good crisis go to waste” in reference to his belief that the war’s lessons and hardships could forge a new paradigm for economic cooperation and development. Fast forward 75 years, and the world is emerging from another crisis – a global pandemic that changed many facets of our lives. Industrial manufacturing is seeing changes too. Already faced with the imminent retirement of the baby-boomer generation and the corporate amnesia that goes along with it, progressive companies are using the COVID-19 crisis to rethink how even the most basic tasks can be accomplished more effectively. This has resulted in the adoption of disruptive technologies that pave the way for a quantum shift in how asset-intensive industries run their businesses. This trend is particularly true in the world of asset-condition management. Gone are the days when companies could afford to “fix it when it breaks.” Upper-quartile-performing companies are looking to technology to supplement and in many cases replace their strategies for condition management. Historically, conditioning monitoring – a key enabler of asset-condition management – has focused on three technologies to gauge the health of hydraulics and lubricated assets: vibration analysis, oil analysis, and ultrasound. Combined, these three technologies are capable of detecting and isolating many of the root causes of poor reliability. Traditionally, asset-condition monitoring has been deployed using a labor- and skills-intensive route-based model. Each month, a technician walks a defined route, taking readings or extracting oil samples from each critical asset. After capturing this data, someone has to

AUGUST 2021

predict trends and make judgement calls on the condition of each asset. Done correctly, route-based condition monitoring can be effective at improving asset reliability. But it has limitations, not the least of which is the fact that the data is merely a snapshot of the moment it is captured. In some instances, this limitation can prevent the accurate diagnosis of transient issues. In the past few years, remote condition monitoring has emerged as technology has improved and costs have come down. Real-time access to data yields a more accurate diagnosis of problem conditions, highlighting the impact of daily maintenance or operations on asset health. Already gaining broader appeal and acceptance, the global pandemic has kick-started this new industrial revolution into high gear. This change in condition monitoring is particularly apparent in the world of lubrication and hydraulic fluid-condition management. Traditional lab-based tests such as viscosity, acid number, water content, particle counting, and wear debris analysis have been augmented

by low-cost, high-quality sensors that provide an accurate, real-time assessment of oil condition, contamination levels, and machine health. To best support this growing trend, Des-Case recently launched an IIoT-based connected platform called IsoLogic, which connects a series of sensors – oil quality, contamination, moisture, ferrous debris, and the world’s first connected desiccant breather – to a single IIoT platform. Combined with an intuitive dashboard, IsoLogic provides real-time insight on the health and cleanliness of the lubricant and the machine. Combined with decades of lubrication and fluid power subject matter expertise, IsoLogic allows our customers to pinpoint emergent issues quickly and evaluate every aspect of lubricant and fluid management throughout the plant. Perhaps the most promising aspect of realtime fluid management is the ability to correlate changes in oil health or cleanliness with daily maintenance and operations activities. Issues such as incorrect oil additions, low oil level, or seal failure – problems that may have gone undetected without real-time 24/7 data – can be quickly and accurately diagnosed. In the world of asset management, as in life, change is inevitable. Fortunately, not all changes are bad. As we emerge into a post-COVID world, the way we manage and assess assets is forever changed. For companies that embrace change, the switch to real-time fluid management will show dividends for many years to come, long after the latest crisis is a distant memory. 

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Don’t compromise! PUBLISHER Innovative Designs & Publishing, Inc. 3245 Freemansburg Avenue, Palmer, PA 18045-7118 Tel: 800-730-5904 or 610-923-0380 Fax: 610-923-0390 • Email: Art@FluidPowerJournal.com www.FluidPowerJournal.com Founders: Paul and Lisa Prass Associate Publisher: Bob McKinney Editor: Michael Degan Technical Editor: Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPSD, CFPMT, CFPCC - CFPSOS LLC Director of Creative Services: Erica Montes Eastern Region Acct Executive: Norma Abrunzo Accounting: Donna Bachman, Sarah Varano Circulation Manager: Andrea Karges INTERNATIONAL FLUID POWER SOCIETY 1930 East Marlton Pike, Suite A-2, Cherry Hill, NJ 08003-2141 Tel: 856-489-8983 • Fax: 856-424-9248 Email: AskUs@ifps.org • Web: www.ifps.org 2021 BOARD OF DIRECTORS President: Rocky Phoenix, CFPMMH - Open Loop Energy, Inc. Immediate Past President: Jeff Kenney, CFPMHM, CFPIHM, CFPMHT - Dover Hydraulics South First Vice President: Denis Poirier, Jr., CFPAI/AJPP, CFPHS, CFPIHM, CFPCC - Eaton Corporation Treasurer: Jeff Hodges, CFPAI/AJPP, CFPMHM - Altec Industries, Inc. Vice President Certification: James O’Halek, CFPAI/AJPP, CFPMIP, CMPMM - The Boeing Company Vice President Marketing: Scott Sardina, PE, CFPAI, CFPHS Waterclock Engineering Vice President Education: Randy Bobbitt, CFPAI, CFPHS Danfoss Power Solutions Vice President Membership: John Bibaeff, PE, CFPAI, CFPE, CFPS

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DIRECTORS-AT-LARGE Chauntelle Baughman, CFPHS - OneHydraulics, Inc. Stephen Blazer, CFPE, CFPS, CFPMHM, CFPIHT, CFPMHT Altec Industries, Inc. Randy Bobbitt, CFPAI, CFPHS - Danfoss Power Solutions Steve Bogush, CFPAI/AJPP, CFPHS, CFPIHM - Poclain Hydraulics Cary Boozer, PE, CFPE - Motion Industries, Inc. Lisa DeBenedetto, CFPS - GS Global Resources Daniel Fernandes, CFPECS, CFPS - Sun Hydraulics Brandon Gustafson, PE, CFPE, CFPS, CFPIHT, CFPMHM - Graco, Inc. Garrett Hoisington, CFPAI/AJPP, CFPS, CFPMHM Open Loop Energy Brian Kenoyer, CFPHS - Five Landis Corp. Jon Rhodes, CFPAI, CFPS, CFPECS - CFC Industrial Training Mohaned Shahin, CFPS - Parker Hannifin Randy Smith, CFPHS - Northrop Grumman Corp. EXECUTIVE DIRECTOR (EX-OFFICIO) Donna Pollander, ACA HONORARY DIRECTORS (EX-OFFICIO) Paul Prass, Fluid Power Journal Liz Rehfus, CFPE, CFPS Robert Sheaf, CFPAI/AJPP, CFC Industrial Training

IFPS STAFF Executive Director: Donna Pollander, ACA Communications Director: Adele Kayser Technical Director: Thomas Blansett, CFPS, CFPAI Assistant Director: Stephanie Coleman Certification Coordinator: Kyle Pollander Bookkeeper: Diane McMahon Administrative Assistant: Beth Borodziuk

Fluid Power Journal (ISSN# 1073-7898) is the official publication of the International Fluid Power Society published monthly with four supplemental issues, including a Systems Integrator Directory, Off-Highway Suppliers Directory, Tech Directory, and Manufacturers Directory, by Innovative Designs & Publishing, Inc., 3245 Freemansburg Avenue, Palmer, PA 18045-7118. All Rights Reserved. Reproduction in whole or in part of any material in this publication is acceptable with credit. Publishers assume no liability for any information published. We reserve the right to accept or reject all advertising material and will not guarantee the return or safety of unsolicited art, photographs, or manuscripts.

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AUGUST 2021

Speaking of Hydraulics FILTERS AND FLUID THAT TALK By Nate Zambon, Director of Filter Minder, Donaldson Company

AUGUST 2021

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With good filtration, it’s not unheard of to get up to 7,000 hours of operation from some of today’s advanced hydraulic fluids.

the end of the day, it’s all about uptime. Whether you manage a fleet of overthe-road freight haulers, maintain an armada of mining equipment, or harvest a few hundred acres of corn, every minute of downtime is money leaving your pocket. When thinking about thorough filtration in regard to equipment uptime, the mind immediately jumps to the engine. Filtration of the engine oil, fuel, and air is a routine part of maintenance, and understandably so. If one of those filters clogs or, even worse, allows contamination of the system, work can come to a sudden halt. But hydraulic filtration is also important to the bottom line. If a hydraulic component fails due to sudden fluid contamination or longterm wear and tear, it might not be so simple to replace, especially for heavier equipment. With good filtration, it’s not unheard of to get up to 7,000 hours of operation from some of today’s advanced hydraulic fluids. With this long-term reliability, it can be easy to filter and forget because even contaminated oil won’t often result in a catastrophic event that takes a system offline. Many vehicles don’t have warning lights or signals that tell the operator when a hydraulic filter has gone into bypass, let alone if there’s some other problem with the fluid or system. Because hydraulic fluid breakdown generally doesn’t result in a sudden stoppage of equipment, fleet managers often rely on the manufacturer’s recommended hours of operation or regular maintenance intervals. So how would you even know if contaminated fluid was slowly causing wear and tear within a hydraulic system? If a filter plugged and entered bypass mode, how would you know the fluid was unprotected unless you checked it during a WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

regular maintenance interval? What if viscosity broke down for an unknown reason? In short, if there’s a problem with hydraulic fluid, by the time you discover it through regular checks, it might be too late.

‘Talking’ fluid Donaldson’s Filter Minder Connect monitoring solution allows hydraulic filters and fluid to “talk” to the operator. This cloud-based technology puts operators in constant contact with oils and filters, and now that it extends to hydraulics, we’re seeing benefits beyond simply knowing when to change the filter. For example, in the past it was important to avoid waiting too long to change the oil or filters. No one wants a plugged filter entering bypass mode or fluid breaking down and doing more damage than good. But by constantly monitoring the fluid condition and filter status, operators can also avoid changing them too early. Downtime is downtime, and eliminating a service interval through real-time understanding of a hydraulic system minimizes downtime and maximizes uptime. As profit margins grow thinner, it becomes more important to get the most out of every component. While telematics tech like Filter Minder Connect offer important information on vital engine and hydraulic systems on a vehicle, that data can be overwhelming to an operator or fleet manager who may not know what it means. While a fleet manager might be too busy to know what a sudden drop in filter pressure might mean for the immediate future, cloudbased information can tell the manager, “You’re approaching a service event,” or even, “It’s time to coordinate a filter replacement.”

Real-time answers to questions about a fluid’s quality or its age can help operators make informed decisions about the best time to perform maintenance. Raw data doesn’t matter unless you can interpret what it means for the equipment. Even with the telematics advances, hydraulic fluid and filter maintenance still often boils down to the tried-and-true measurements of time and distance. The book says it’s time to change my fluid, so I’m going to do it. And since I’m doing that, I might as well change the filter, right? It just makes good sense to kill those two birds at once.

Saving on costs But hydraulic fluid isn’t cheap, and there can be hundreds of gallons in a single reservoir. What if 75% of the fluid’s life is left? Not changing it saves costs, manpower, and equipment downtime. The converse is also true: being told by the equipment that there’s something wrong with the filter or fluid can save thousands of dollars down the road. The traditional process to analyze hydraulic oil can take weeks. Technology like Filter Minder Connect dramatically eliminates that with data generation that simply tells the operator it’s time to change the oil. These advances in telematics technology have one ultimate goal: less downtime. Downtime costs money to fix problems that could have been foreseen. We now have technology that collects integrated data from critical onboard systems – engine air intake, fuel, oil, and hydraulics – into a single fleet-management platform. But the data also helps lower the costs of owning and operating equipment. And that’s the bottom line. AUGUST 2021

A PRIMER ON FLUID POWER nce during a discussion about a mobile fluid power application, a colleague kept referring to what he called “voodoo hydraulics.” This curious phrase illustrated the many and often misunderstood differences between mobile and industrial fluid power. As with industrial fluid power, mobile fluid power automates a machine and makes it move. Most of the time you’ll find mobile fluid power in machines with tracks or tires that are outdoors in the elements. But mobile fluid power refers not only to the type of machine, it also refers to types of hydraulic components and circuits used to control the machine. This article discusses how mobile fluid power works and how it is different from industrial fluid power. In most cases the human-machine interface between mobile and industrial equipment is very different. Many industrial applications are automated. Programmable logic controllers and programming allow the machines to run a large number of functions based on sensor or user inputs. Most of the time, with mobile equipment the human-machine interface is much more intimate. The movement of a lever or joystick or the push of a proportional thumbwheel directly affects the machine’s movement. It gives the operator the ability to get the “feel” of the machine, much like driving a car. Another big difference between mobile and industrial equipment is the prime mover. Mobile machinery regularly uses the vehicle’s engine-driven system (its internal combustion engine) for the prime mover; in industrial applications, it’s usually powered with an electric 8

AUGUST 2021

By Joe Raccosta, Fluid Power Sales Manager, and Micah Taylor, Mobile Fluid Power Manager, Milwaukee Division, Motion

motor. However, there is an overlap. For example, open loop pumps (vane and piston) are used in both segments but are more prevalent in industrial systems, whereas closed loop pumps are more frequently used in mobile systems. Screw-in cartridge valves are used in many manifold assemblies across both platforms as well. Both segments use cylinders, but mobile tends to use more welded and telescopic types than industrial. As far as fluid conveyance, mobile applications often operate at higher pressures and need hose with higher pressure ratings. They also require corrosion-resistant fittings for environmental protection, as well as abrasive-resistant hose because of machinery movement. Later in the article, we will describe some of the more common components found in a mobile system.

As with other segments of industry, mobile fluid power has unique characteristics and challenges. Some of those characteristics are duty cycle, environment, modular size, and noise and shock. Duty cycle. Duty cycle is the ratio of time a load or circuit is on compared to the time the load or circuit is off. The duty cycle on hydraulic pumps is the number of minutes in each hour the pump is under load. If you place a lower-efficiency, lighter-duty pump into a higher-duty cycle application, the life of the pump is compromised. Each subsegment of mobile equipment has varying

duty cycles, and some applications may require higher-duty cycles than others. Corrosion resistance. Mobile equipment operates within a wide scope of environmental conditions. Mobile equipment must be compact yet powerful, with performance unhindered by environmental factors like rain, snow, ice, dirt, extreme heat, or moisture. These environmental factors typically don’t come into play in the design or performance of industrial equipment. With these environmental challenges, mobile hydraulic components require anticorrosion agents for preventive measures. Size, weight, and power output. Size, weight, and power output are crucial in mobile applications. Mobile components are typically smaller, modular, and lighter compared to industrial components. Take a reservoir, for example. On an industrial system, it is usually sized around three times the flow of the pump’s output, whereas in a mobile system the reservoir size could be as small as the output of the pump or less. Producing the power output required with less space and weight is crucial. That is why power density is a major factor in mobile hydraulic circuits. Power density is the power output per unit volume, or the power output as a ratio of the actuator size. Power density is one reason why hydraulics is so important to mobile machinery. Mobile systems require high-output power combined with minimum weight. Noise, shock, and vibration. Mobile systems tend to have higher noise, shock, and vibration challenges because of improper human operation or extreme and rugged operating conditions. Because of the environment in WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

which mobile systems operate, they generally do not have strict noise (dB) specifications like an industrial system and tend to operate at higher dB levels. An example of shock occurs when a loader operator runs the bucket in “shake mode,” that is, starting and stopping the bucket’s movement quickly to break loose stuck materials. That sudden start-and-stop motion adds shock to the hydraulic system. Vibration is another challenge from both the machine’s engine and terrain conditions. Uneven and rough terrain can cause vibration as well as pressure pulsations originating from the hydraulic system. Another factor is user error. Again, the operator can cause some of these issues by having the machine make sudden and erratic movements, leading to abrupt changes of pump displacement and actuator positions, causing additional vibration. Now we’ll look at some common mobile fluid power components.

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Image courtesy Salami SpA.

Both industrial and mobile systems use gear, vane, and piston pumps. The main drivers behind mobile-component design are weight, space, environment, and performance characteristics. Historically, noise has not been a huge factor, but more stringent regulations and exports to Europe are changing that. Piston pumps are the most expensive of the three types but offer the most control options and highest operating pressures. In general, gear pumps fall between the piston and vane on both operating pressure and price. They can be a bit noisy depending on the gear design. Vane pumps have historically been the least expensive type. They tend to operate at a lower noise level and offer a number of pump controls. Before discussing pump controls, there must be a basic understanding of what fixed and variable displacement means. A fixed pump always has the same displacement no matter the pressure. The input speed at which the pump turns can change the output flow, but the physical displacement of the pump always remains the same. With a variable displacement pump, the oil volume output can change based on the displacement change. This can be done in several different ways with a variety of pump controls. By far, the most common controls in the mobile world are the pressure compensator and load sense. If a pump is outfitted with a pressure-compensator control, it sits at maximum displacement until the prime mover is turned on. As the pump immediately creates flow, pressure

starts to build. As the pressure builds to a predetermined setting, the pump mechanically destrokes, or reduces the pump displacement to zero. It stays at zero until a machine function is operated. At that point, the pump flows oil to the function as quickly as physically possible. One advantage of this system is that it reacts quickly. This type of control is a good choice for a mobile machine such as a telehandler, in which the operator wants no lag between joystick operation and a function move. The disadvantage of a pressure-compensated system is that it is always at the maximum compensator pressure setting, or high-pressure standby. So if high-flow low-pressure functions are run, the net result is a high-pressure drop between the pump and actuator, resulting in heat. Load sense is a variation of the pressure-compensator control but takes it a step further. Just as with the pressure-compensator control, when the machine is off, the pump sits at maximum displacement via a bias spring. When the prime

An open-center sectional valve commonly used in mobile applications.

mover turns on, the pump starts to create flow and pressure builds. But instead of reaching the compensator setting, the load-sense control destrokes the pump at a lower predetermined setting, referred to as low-pressure standby. A common low-pressure standby setting is 300 psi (21 bar). The advantage of the load-sense pump is that it is very efficient if used on a machine that can see many different load conditions or pressures. The disadvantage is that you must use a load-sense valve with the pump. That adds cost and complexity to the overall system. There are many controls available for mobile equipment including horsepower limiting, electroproportional displacement, hydraulic pilot control, and more. But the load-sense system is one of the most popular on mobile equipment. It’s not always the case, but in general it seems piston and gear pumps have taken over

the mobile market. Many applications can run between 3,000 and 4,000 psi (207 and 276 bar) maximum operating pressure, with many maxing out at 3,000 psi (207 bar), making the gear pump a possibility depending on the control scheme. The outlier is the hydrostatic drive pump that routinely has a maximum operating pressure of up to 6,000 psi (414 bar).

Among all the product categories, the directional control valve probably differs more than any other. It is common in that it can control the direction and flow of oil. But virtually everything else is different in size, shape, weight, corrosion-resistant options, electrical connectors, and so on. There is a gray area, because it is still common to see small industrial valves – sizes D03 and D05 – on mobile machinery. Mobile directional control valves come in two forms: monoblock and sectional. A monoblock valve has one body but can have up to eight spools within that body. Many are available in tandem, parallel, or series circuits. These valves are less expensive but also less flexible. Monoblocks are a good choice for equipment manufacturers that use the same valve repeatedly. Sectional valves have an individual spool in each body, or section. The sections are held together with tie rods. Typically eight to twelve sections can be stacked together depending on the particular valve’s manufacture and size. This type of modular valve allows for many different combinations of options, making it an attractive solution for end users and equipment manufacturers alike. There are two types of mobile valve circuits: open center and closed center. Open center. Open-center circuits consist of a fixed-displacement pump and an open-center type mobile directional control valve. The fixed pump (typically gear) creates constant oil flow, which flows through the directional control valve and back to tank at a low-pressure drop. When the valve is operated, the main spool moves and starts to cut off the flow to tank and redirect it to the valve work ports. As the spool continues to stroke, more oil flow is directed to the work port and less to tank. When the spool strokes fully, 100% of the flow is redirected to the work port. Within the open-center valve platform, there are three common circuit options, described as parallel, tandem, and series. The schematic (Continued on page 10) AUGUST 2021

(Continued from page 9)

Image courtesy Eaton

A closed-center load-sense sectional valve, commonly used in mobile applications.

AUGUST 2021

Circuits courtesy Motion

symbols of each circuit show the pressure, neutral, and tank passages (see illustrations at right). In a parallel circuit, the main inlet pressure is connected to all the spool, or section, P ports through one main pressure core or passage. In this case, if multiple functions are run, the oil can take the path of least resistance and cause a function to slow or stop. In a tandem circuit, the main pressure passage is cut off between each section, allowing oil to be directed through a neutral passage only. If each section in a valve stack is tandem, the upstream section will always have flow priority. The oil coming out of the actuator (cylinder or motor) is directed by the spool back to the tank port via the tank passage. In a series circuit, the pressure passage is cut off between each section but allows oil to run through the neutral core. After the oil returns from the actuator (cylinder or motor), it flows over the spool, but instead of going back to tank, it is routed to the next section’s pressure passage. This allows 100% of the oil flowing into the valve to go through each actuator and run them in series. Closed center. Closed-center valves do not allow oil to flow through the valve and back to tank but will block the flow completely. In cases where this type of valve is used, a variable-displacement pressure-compensated pump is required. When the prime mover is turned on, the pump will destroke at a predetermined pressure. When a function is operating, the pressurized oil moves the actuator responsively. Load-sense valves are more complex. They are closed center and must be used with a variable-displacement pressure-compensated load-sense pump control. The added loadsense function works like this: When the valve is operated, a load-sense signal is generated and directed back to the pump control via a separate load-sense line, allowing the pump to stroke and develop flow. This type of system is an advantage when there are varying flow and pressure requirements. The correct flow is provided at load pressure plus the set stand-by pressure.

Load-sense systems can be split into two technologies: precompensated and postcompensated. The precompensated valve is the original technology. The disadvantage is that when the machine calls for more flow than the pump can offer, the highest pressure function slows or completely stops (path of least resistance). The operation of the postcompensated

valve is different. When the machine calls for more flow than the pump can offer, all the functions slow down proportionally. The main advantage of the postcompensated system is it does not allow any one function to stop, which gives the operator more predictive and consistent control of the machine under varying operating conditions. WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

Steering control units, often referred to as steering orbitrols, are components much more frequently found in a mobile application than in an industrial application. They are used in conjunction with a column and wheel to steer a machine. Applications include lawn and garden, lift trucks, construction, forestry, agricultural vehicles, dump trucks, forklifts, and tractors.

Motors, like pumps, are available in vane, gear, and piston design. The performance and cost comparisons between them are the same as well. No matter what the technology used, hydraulic motors seem to cross over the most out of all the product categories. Motors come in several mounting configurations and are used to turn tracks, wheels, augers, mixers, swing drives, and more on a variety of mobile equipment.

Another technology attributed to mobile hydraulics is the hydrostatic transmission. Often it is used as a ground drive to propel machines but found on many motor circuits where reversing direction and variable flow is required. The hydrostatic pump and motor both have two pressure ports, A and B. The ports are connected or “looped” together so that the oil that comes out of the motor goes directly back into the pump. The pump itself can supply oil out of WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Image courtesy Motion

Cylinders are available in an infinite number of sizes, configurations, and complexities. There are standard “off-the-shelf” cylinders as well as customized cylinders with mounted manifolds for load holding or other hydraulic circuits. Like industrial fluid power systems, cylinders in mobile systems are very application-specific, including the telescopic cylinders used on applications such as dump trucks. Most of the cylinders that we see on mobile equipment are of a welded design, versus the tie-rod and milltype cylinders found on industrial equipment. Not to exclude the telescopic cylinders used on applications such as dump trucks.

3D model of a custom manifold assembly.

the A or B port. That is what allows the motor to reverse. What makes the motor unique is that it often has a hot-oil shuttle built right into it that strips oil out of the loop so it can run through a filter or heat exchanger. In the hydrostatic pump, a small gear pump – referred to as the charge pump – replenishes the oil that was stripped away by the hot-oil shuttle and the case drains. Hydrostatic transmissions are used in applications like tractors, forestry machines, golf course maintenance equipment and more.

Cartridge valves were created because equipment manufacturers demanded more flexibility in the design of their hydraulic systems and the industry demand for refinements to their line-mounted hydraulic systems to a more compact design. The result is a more simplified installation appearance of the system and fewer hydraulic hoses, fittings, and mounting brackets, eliminating many leakage problems. Cartridge valves are commonly used to control oil pressure, direction, and flow. Valves are either spool, poppet, or ball check design. Screw-in cartridges are very compact and produce inexpensive circuits that are reliable and easy to maintain. Screw-in cartridges are most often part of a machined manifold but also are available in individual bodies. Custom machined manifolds with cartridge

valves compress the overall envelope size by combining valving and plumbing into one complete package. Installation and maintenance of custom manifolds are more simplified when compared to traditional, line-mounted valve systems. The need to connect valves by hydraulic hoses and fittings is reduced using internal passages machined into the manifold block. By designing one or more manifold blocks into a system, the time and cost of installing the hydraulic system are much less than traditional, linemounted valve systems. Advantages for OEMs using a custom manifold block with cartridges are greater design flexibility, lower installed cost, smaller package size, less external leakage, easier troubleshooting, easier maintenance, organized plumbing, and lower noise levels. Compact manifold assemblies reduce the system size and weight, allowing for smaller, more efficient mobile applications. The differences between mobile and industrial hydraulics have evolved in response to the performance and environmental requirements of the equipment being produced. These industries are evolving with various demands of technology, flexibility of systems, cost savings, and efficiency requirements. Fluid power products and solutions specific to mobile or industrial equipment continue to evolve. Although hydraulic components serve similar functions across both segments, understanding differences between these components’ functionalities, their applications, and how the machinery operates benefits equipment users and designers alike. 

AUGUST 2021

FIGURE IT OUT

Robert Sheaf has more than 45 years troubleshooting, training, and consulting in the fluid power field. Email rjsheaf@cfc-solar. com or visit his website at www. cfcindustrialtraining.com.

RETRACT TO EXPAND

COIL

EXPAND SOL. A

D07 VICKERS TOP RACINE MAIN STAGE

121" PIPE

VICKERS 0FM - 202

HH9660024DNUBT PALL PRESSURE FILTER HC9600FDN16H

New Problem

Pilot Operated Directional Valve Locks Up

COLLAPSED SOL. B

0 - 3000 PSI

30 HP 1200

By Robert Sheaf, CFPAI/AJPP, CFPE, CFPS, CFPECS, CFPMT, CFPMIP, CFPMMH, CFPMIH, CFPMM, CFC Industrial Training

40 GPM

PALL FILTER HC0293SEE5

1000 PSI

120 GAL TANK

I GOT A call to help with a problem on an aluminum uncoiling station. The customer would collapse the expander that held the coil and installed a new coil to unwrap. They would cycle the directional valve back and forth while properly positioning the coil. If they were having trouble and cycled the directional valve more than four to six times, the valve would lock up and wouldn’t shift in either direction. They would call maintenance to troubleshoot the problem and, depending how quickly maintenance arrived, the valve would either cycle or lock up. The longer it took, the better chance the valve would then work. But if they cycled it several times, it would lock up. The directional valve and PO check were mounted close to the expander, while the power unit was about 30 feet away. The pump did supply oil to three other functions that had directly operated valves, and they worked well. They replaced the directional valve with a new one, and it would cycle 10 to 12 times and then lock up. What could be causing the problem?

Solution to July 2021 problem:

BLOW MOLDING NOZZLE CONTROL CYLINDER

Servo System Pump Keeps Failing After inspecting the system where the pressurecompensated pumps were failing, I wondered why there was not a spike-suppressant directly operated relief valve to keep the pressure spikes under control. The designer had used the accumulator to soften the system and control the pressure spikes. I found the bladder in the accumulator had failed. To view previous problems, visit www. fluidpowerjournal.com/figure-it-out.

RETURN FILTER

MOOG SERVO VALVE

DIAPHRAGM ACCUMULATOR

PRESSURE FILTER

LIFT HANDLE

HINGED TOP

SET AT 2000 PSI

FLOODED SUCTION LINE HOSE

AUGUST 2021

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

I F P S U P D AT E

IFPS Names Hall of Fame Inductees

TO MARK FLUID Power Professionals’ Day in June, the International Fluid Power Society announced nine inductees to the Fluid Power Hall of Fame. They will be honored at an Oct. 6 ceremony during IFPS’s annual meeting in Reno, Nevada. Two inductions are posthumous. PETER A.J. ACHTEN Peter A.J. Achten, Ph.D., holds over 40 individually titled worldwide patents and has authored more than 200 survey reports, papers, articles, and books. He has presented speeches, workshops, and lectures around the world in several languages. Achten was awarded the Robert E. Koski Medal in 2019 and the Joseph Bramah Medal in 2008. TIMOTHY R. BAILEY Australian Timothy R. Bailey helped develop several of his country’s fluid power organizations and has served as president of the Western Australian Fluid Power Society, the International Fluid Power Society Australia, the Fluid Power Society Australia, and the Fluid Power Society (WA). He helped create the original WAFPS Curriculum Matrix. He has focused on safety throughout his career. JIM BRIZZOLARA Jim Brizzolara cofounded HydraForce in 1985. The company has won awards and accolades throughout the industry. With a strong emphasis on community involvement and student training, HydraForce has supported students, suppliers, and employees through more than $400,000 in grants, tuition support, and training programs, including full sponsorship for the Wheeling High School robotics lab. GEORGE DOIG After his service in the U.S. Navy during World War II, George Doig and three others founded Numatics in 1953. In the 1950s, Doig became one of 30 founders of IFPS and chapter 1 in Detroit. In 1966 he coauthored the book “Practical Air Circuitry.” He founded manufacturers’ representative Doig Associates in 1972. He holds four air control patents and was a certified fluid power engineer from 1994 to 2010.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

CELEBRATING 60 YEARS

CRAIG M. FOX Craig M. Fox served as technical editor for the Lightning Reference Handbook. He worked for Eaton Corporation in Maumee, Ohio, as a senior technical trainer and contributed to Eaton’s Industrial Hydraulics Manual. He is an active member of the electronic technology curriculum review board for the College of the Canyons in Santa Clarita, California. MEDHAT KHALIL Medhat Khalil, Ph.D., won the 2012 Otto Maha Pioneer in Fluid Power award and is in his 16th year as the director of professional education and research development for the Applied Technology Center of the Milwaukee School of Engineering. He has contributed to the specification and commissioning of training labs and centers for MSOE, Concordia University, Egyptian Iron & Steel Company, and the Giza, Egypt, Civil Aviation Authority. He is author of five books. NOAH D. MANRING Noah D. Manring, Ph.D., P.E., has served on the faculty of the Mechanical and Aerospace Engineering Department at the University of Missouri since 1997, becoming dean of engineering in 2020. He has published 44 archival journal papers, 38 conference papers, and three books on fluid power. He holds 12 U.S. patents, including one in 2018 for monitoring cardiovascular disease. He served from 2006 to 2010 as scientific advisory to the Center for Compact and Efficient Fluid Power. HARLEY E. BERGREN (1917-2021) Harley E. Bergren unfortunately passed away March 19, three days before his 104th birthday. Bergren founded Power Systems in Minnesota in 1966. He retired in 1982 but remained a company stockholder until the company was sold in 1998. He developed a unique lawn-mower drive system before hydrostatics was invented, using a cam, a valve, and two gear pumps. In 1967, he obtained the patent for a hydrostatic transmission. RICHARD J. FONTECCHIO (1948-2014) Richard “Dick” Fontecchio began his fluid power career in 1965 at Fluid Power Systems in Glenview, Illinois. In 1985, he cofounded HydraForce with Jim Brizzolara in Northbrook, Illinois. With Fontecchio’s leadership as vice president of sales and marketing, HydraForce released over 15,000 standard and proprietary valves and their electrohydraulic controls. The company grew into the world’s largest supplier of hydraulic and electrohydraulic valves, manifolds, and controls. AUGUST 2021

I F P S U P D AT E

Fluid Power Symbology Guide CELEBRATING 60 YEARS

MEMBER PRICE: $12.85 • NON-MEMBER: $16.00 This 30-page guide presents fluid power symbols commonly used within ISO 1219-1 and 2 standards and illustrates the component function applied within fluid power systems. This Symbology Guide is permitted to be used during an IFPS certification test. Note: ISO 1219 also specifies the drawing size and orientation of drawn components, which is not covered in this booklet; refer to ISO 1219 for further detailed information. HYDRAULIC SYMBOLS • Basic Symbols • Pumps and Motors • Pressure Controls • Logic Valves • Accumulators • Cylinders • Directional Control Valves • Common Directional Control Valves • Fluid Conditioning • Sensors • Flow Controls • Flow Dividers

• Accessory and Misc. Components ELECTRICAL SYMBOLS • Basic Electrical Symbols • Electrical Relay Diagram Symbols • Logic Gate Symbols PNEUMATIC SYMBOLS • Basic Symbols • Air Compressor, Air Motors and Vacuum Components

• • • • •

• • • •

Pressure Controls Logic Elements Cylinders Directional Control Valves Common Directional Control Valves Fluid Conditioning Flow Controls Sensors Accessory and Misc. Components

IFPS Annual Meeting Set for October

THE INTERNATIONAL FLUID Power Society’s annual meeting takes place in person Oct. 5-7 in Reno, Nevada. IFPS hosts the Fluid Power Hall of Fame awards ceremony on Oct. 6. Nine inductees, including two posthumous, will be acknowledged for their significant contributions to the fluid power industry. (See page 13.) The annual meeting is a great way to network with professionals in the industry. To register, visit www.ifps.org.

SCHEDULE OF EVENTS Monday, Oct. 4 8:00 AM - 2:00 PM.............................................. Technical Workshop Tuesday, Oct. 5 8:00 AM - 9:00 AM.............. Strategic Planning Committee Meeting 9:00 AM - 11:00 AM.......................... Education Committee Meeting 11:00 AM - 12:00 PM....................Membership Committee Meeting 12:00 PM - 12:30 PM.................................................... Hosted Lunch 12:30 PM - 1:30 AM.......... Membership Committee Meeting, cont'd 1:45 PM - 5:00 PM........................ Tesla Gigafactory Tour (tentative) 6:00 PM - 9:00 PM...........................Welcome Reception & Jeopardy Wednesday, Oct. 6 8:00 AM - 12:00 AM...................... Certification Committee Meeting 12:00 PM - 1:00 PM...................................................... Hosted Lunch 1:00 PM - 3:30 PM............................. Marketing Committee Meeting 6:00 PM - 9:30 PM Annual Dinner & Hall of Fame Awards Ceremony Thursday, Oct. 7 8:00 AM - 9:30 AM................................Finance Committee Meeting 9:30 AM - 11:00 AM................................ Board of Directors Meeting 11:00 AM - 12:00 PM Strategic Planning Committee Meeting Follow Up 12:00 PM - 1:00 PM........................................... Lunch (on your own) 1:30 PM - 9:00 PM Lake Cruise & Dinner at Lake Tahoe (tentative) 14

AUGUST 2021

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

I F P S U P D AT E

May 2021

Newly Certified Professionals AUTHORIZED JOB PERFORMANCE PROCTOR John Popek, Perfection Servo Hydraulics Adam Smith, Controlled Fluids Inc.

PNEUMATIC SPECIALIST Dylon Ackerman, Bedford Industries Isaac Frieden, Sun Hydraulics

MASTER OF INDUSTRIAL PNEUMATICS holds PT, PM, and CC Certifications Steven Downey, Hydraulic Parts Source

CONNECTOR & CONDUCTOR Ariel Garza, Controlled Motion Solutions Matthew Marquiss, Manitowoc Cranes Kurt Smay, Manitowoc Cranes Dalton Wilson, Manitowoc Cranes

MASTER TECHNICIAN holds IHT, MHT, and PT Certifications Steven Downey, Hydraulic Parts Source SPECIALIST holds HS and PS Certifications Dylon Ackerman, Bedford Industries Isaac Frieden, Sun Hydraulics ELECTRONIC CONTROLS SPECIALIST Alejandro Hernandez, SunSource HYDRAULIC SPECIALIST Alex Adams, Womack Chris Dole Tyler Sorensen, Marmon-Herrington Nicholas Wiebelt, EMI, A Division of W&O

MOBILE HYDRAULIC MECHANIC Enoch Abell, Altec Industries Inc. Christopher Absher, Altec Industries Inc. Francisco Armendariz, Southern California Edison Cole Blanton, American Electric Power Ryan Bruce, Altec Industries Inc. Adrian Caballero, Southern California Edison Omar Cardenas, Southern California Edison Andrew Chapa, American Electric Power Co. Jimmy Cockrell, Terex Utilities Christopher Coffee, Altec Industries Inc. Christopher Coleman, Terex Utilities Stephen Crocker, Altec Industries Inc. Charles Edwards, Terex Utilities Robert Ellsworth Gregory Funderburg, Altec Industries Inc.

Thomas Gardenhire, Terex Utilities Morgan Harris, Terex Utilities Phillip Hernandez, Altec Industries Inc. Chad Hrnjak, Altec Industries Inc. David Kennard, Southern California Edison Dylan Lee, Altec Industries Inc. Jeremy McCutcheon, Terex Utilities Brion Myers, Southern California Edison Robert O'Neil, Altec Industries Inc. John Pettigrew, Southern California Edison Christopher Quigg, Southern California Edison John Quiles, Southern California Edison Jonathan Redden, The Illuminating Co Donald Rowe, Altec Industries Inc. Steve Sanchez, Altec Industries Inc. Heath Schultz, Altec Industries Inc. Seth Shubirg, AEP Matt Singer, AEP Jakob Spurlock, Altec Industries Inc. Daniel Taylor, Altec Industries Inc. Ryan Thomas, Altec Industries Inc. Casey Tucker Jackson Wagner, Altec Industries Inc. Frank Weitoish, First Energy Corp. Ethan Whitson, Altec Industries Inc. Dustin Williams, AEP PNEUMATIC TECHNICIAN Steven Downey, Hydraulic Parts Source

Introducing!

9S SERIES INVESTMENT CAST SWIVELS The “9S” Series swivels represent one of the most complete range of sizes and configurations available to the industry. This series has been redesigned to incorporate a one piece barrel arrangement thus eliminating the need for braze joints. These swivels are pressure balanced with operating pressures up to 5,000 psi. All configurations are designed with a 4:1 Safety Factor and include RoHS compliant zinc plating. P.O. Box 6479, Fort Worth, TX 76115 V. 817/923-1965 www.hydraulicsinc.com

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

AUGUST 2021

I F P S U P D AT E

Certification Testing Locations Individuals wishing to take any IFPS written certification tests can select from convenient locations across the United States and Canada. IFPS is able to offer these locations through its affiliation with the Consortium of College Testing Centers provided by National College Testing Association. Contact headquarters if you do not see a location near you. Every effort will be made to accommodate your needs. If your test was postponed due to the pandemic, please contact headquarters so that we may reschedule.

TENTATIVE TESTING DATES FOR ALL LOCATIONS: September 2021 Tuesday 9/14 • Thursday 9/30 October 2021 Tuesday 10/5 • Thursday 10/28 November 2021 Tuesday 11/2 • Thursday 11/18 December 2021 Tuesday 12/7 • Thursday 12/16

ALABAMA Auburn, AL Birmingham, AL Calera, AL Decatur, AL Huntsville, AL Jacksonville, AL Mobile, AL Montgomery, AL Normal, AL Tuscaloosa, AL ALASKA Anchorage, AK Fairbanks, AK ARIZONA Flagstaff, AZ Glendale, AZ Mesa, AZ Phoenix, AZ Prescott, AZ Scottsdale, AZ Sierra Vista, AZ Tempe, AZ Thatcher, AZ Tucson, AZ Yuma, AZ ARKANSAS Bentonville, AR Hot Springs, AR Little Rock, AR CALIFORNIA Aptos, CA Arcata, CA Bakersfield, CA Dixon, CA Encinitas, CA Fresno, CA Irvine, CA Marysville, CA Riverside, CA Salinas, CA San Diego, CA San Jose, CA San Luis Obispo, CA Santa Ana, CA Santa Maria, CA Santa Rosa, CA Tustin, CA Yucaipa, CA COLORADO Aurora, CO Boulder, CO Springs, CO Denver, CO Durango, CO Ft. Collins, CO Greeley, CO Lakewood, CO Littleton, CO Pueblo, CO DELAWARE Dover, DE Georgetown, DE Newark, DE FLORIDA Avon Park, FL Boca Raton, FL Cocoa, FL Davie, FL Daytona Beach, FL Fort Pierce, FL Ft. Myers, FL Gainesville, FL Jacksonville, FL Miami Gardens, FL Milton, FL New Port Richey, FL Ocala, FL Orlando, FL Panama City, FL Pembroke Pines, FL Pensacola, FL Plant City, FL Riviera Beach, FL Sanford, FL

AUGUST 2021

Tallahassee, FL Tampa, FL West Palm Beach, FL Wildwood, FL Winter Haven, FL GEORGIA Albany, GA Athens, GA Atlanta, GA Carrollton, GA Columbus, GA Dahlonega, GA Dublin, GA Dunwoody, GA Forest Park, GA Lawrenceville, GA Morrow, GA Oakwood, GA Savannah, GA Statesboro, GA Tifton, GA Valdosta, GA HAWAII Laie, HI IDAHO Boise, ID Coeur d ‘Alene, ID Idaho Falls, ID Lewiston, ID Moscow, ID Nampa, ID Rexburg, ID Twin Falls, ID ILLINOIS Carbondale, IL Carterville, IL Champaign, IL Decatur, IL Edwardsville, IL Glen Ellyn, IL Joliet, IL Malta, IL Normal, IL Peoria, IL Schaumburg, IL Springfield, IL University Park, IL INDIANA Bloomington, IN Columbus, IN Evansville, IN Fort Wayne, IN Gary, IN Indianapolis, IN Kokomo, IN Lafayette, IN Lawrenceburg, IN Madison, IN Muncie, IN New Albany, IN Richmond, IN Sellersburg, IN South Bend, IN Terre Haute, IN IOWA Ames, IA Cedar Rapids, IA Iowa City, IA Ottumwa, IA Sioux City, IA Waterloo, IA KANSAS Kansas City, KS Lawrence, KS Manhattan, KS Wichita, KS KENTUCKY Ashland, KY Bowling Green, KY Erlanger, KY Highland Heights, KY Louisville, KY Morehead, KY

LOUISIANA Bossier City, LA Lafayette, LA Monroe, LA Natchitoches, LA New Orleans, LA Shreveport, LA Thibodaux, LA MARYLAND Arnold, MD Bel Air, MD College Park, MD Frederick, MD Hagerstown, MD La Plata, MD Westminster, MD Woodlawn, MD Wye Mills, MD MASSACHUSETTS Boston, MA Bridgewater, MA Danvers, MA Haverhill, MA Holyoke, MA Shrewsbury, MA MICHIGAN Ann Arbor, MI Big Rapids, MI Chesterfield, MI Dearborn, MI Dowagiac, MI East Lansing, MI Flint, MI Grand Rapids, MI Kalamazoo, MI Lansing, MI Livonia, MI Mount Pleasant, MI Sault Ste. Marie, M Troy, MI University Center, MI Warren, MI MINNESOTA Alexandria, MN Brooklyn Park, MN Duluth, MN Eden Prairie, MN Granite Falls, MN Mankato, MN MISSISSIPPI Goodman, MS Jackson, MS Mississippi State, MS Raymond, MS University, MS MISSOURI Berkley, MO Cape Girardeau, MO Columbia, MO Cottleville, MO Joplin, MO Kansas City, MO Kirksville, MO Park Hills, MO Poplar Bluff, MO Rolla, MO Sedalia, MO Springfield, MO St. Joseph, MO St. Louis, MO Warrensburg, MO MONTANA Bozeman, MT Missoula, MT NEBRASKA Lincoln, NE North Platte, NE Omaha, NE NEVADA Henderson, NV Las Vegas, NV North Las Vegas, NV Winnemucca, NV

CELEBRATING 60 YEARS

NEW JERSEY Branchburg, NJ Cherry Hill, NJ Lincroft, NJ Sewell, NJ Toms River, NJ West Windsor, NJ NEW MEXICO Albuquerque, NM Clovis, NM Farmington, NM Portales, NM Santa Fe, NM NEW YORK Alfred, NY Brooklyn, NY Buffalo, NY Garden City, NY New York, NY Rochester, NY Syracuse, NY NORTH CAROLINA Apex, NC Asheville, NC Boone, NC Charlotte, NC China Grove, NC Durham, NC Fayetteville, NC Greenville, NC Jamestown, NC Misenheimer, NC Mount Airy, NC Pembroke, NC Raleigh, NC Wilmington, NC NORTH DAKOTA Bismarck, ND OHIO Akron, OH Cincinnati, OH Cleveland, OH Columbus, OH Fairfield, OH Findlay, OH Kirtland, OH Lima, OH Maumee, OH Newark, OH North Royalton, OH Rio Grande, OH Toledo, OH Warren, OH Youngstown, OH OKLAHOMA Altus, OK Bethany, OK Edmond, OK Norman, OK Oklahoma City, OK Tonkawa, OK Tulsa, OK OREGON Bend, OR Coos Bay, OR Eugene, OR Gresham, OR Klamath Falls, OR Medford, OR Oregon City, OR Portland, OR White City, OR PENNSYLVANIA Bloomsburg, PA Blue Bell, PA Gettysburg, PA Harrisburg, PA Lancaster, PA Newtown, PA Philadelphia, PA Pittsburgh, PA Wilkes-Barre, PA York, PA

SOUTH CAROLINA Beaufort, SC Charleston, SC Columbia, SC Conway, SC Graniteville, SC Greenville, SC Greenwood, SC Orangeburg, SC Rock Hill, SC Spartanburg, SC TENNESSEE Blountville, TN Clarksville, TN Collegedale, TN Gallatin, TN Johnson City, TN Knoxville, TN Memphis, TN Morristown, TN Murfreesboro, TN Nashville, TN TEXAS Abilene, TX Arlington, TX Austin, TX Beaumont, TX Brownsville, TX Commerce, TX Corpus Christi, TX Dallas, TX Denison, TX El Paso, TX Houston, TX Huntsville, TX Laredo, TX Lubbock, TX Lufkin, TX Mesquite, TX San Antonio, TX Victoria, TX Waxahachie, TX Weatherford, TX Wichita Falls, TX UTAH Cedar City, UT Kaysville, UT Logan, UT Ogden, UT Orem, UT Salt Lake City, UT VIRGINIA Daleville, VA Fredericksburg, VA Lynchburg, VA Manassas, VA Norfolk, VA Roanoke, VA Salem, VA Staunton, VA Suffolk, VA Virginia Beach, VA Wytheville, VA WASHINGTON Auburn, WA Bellingham, WA Bremerton, WA Ellensburg, WA Ephrata, WA Olympia, WA Pasco, WA Rockingham, WA Seattle, WA Shoreline, WA Spokane, WA WEST VIRGINIA Ona, WV WISCONSIN La Crosse, WI Milwaukee, WI Mukwonago, WI

WYOMING Casper, WY Laramie, WY Torrington, WY CANADA ALBERTA Calgary, AB Edmonton, AB Fort McMurray, AB Lethbridge, AB Lloydminster, AB Olds, AB Red Deer, AB BRITISH COLUMBIA Abbotsford, BC Burnaby, BC Castlegar, BC Delta, BC Kamloops, BC Nanaimo, BC Prince George, BC Richmond, BC Surrey, BC Vancouver, BC Victoria, BC MANITOBA Brandon, MB Winnipeg, MB NEW BRUNSWICK Bathurst, NB Moncton, NB NEWFOUNDLAND AND LABRADOR St. John’s, NL NOVA SCOTIA Halifax, NS ONTARIO Brockville, ON Hamilton, ON London, ON Milton, ON Mississauga, ON Niagara-on-the-Lake, ON North Bay, ON North York, ON Ottawa, ON Toronto, ON Welland, ON Windsor, ON QUEBEC Côte Saint-Luc, QB Montreal, QB SASKATCHEWAN Melfort, SK Moose Jaw, SK Nipawin, SK Prince Albert, SK Saskatoon, SK YUKON TERRITORY Whitehorse, YU UNITED KINGDOM Elgin, UK GHAZNI Kingdom of Bahrain, GHA Thomasville, GHA EGYPT Cairo, EG JORDAN Amman, JOR NEW ZEALAND Taradale, NZ

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

I F P S U P D AT E

AVAILABLE IFPS CERTIFICATIONS CFPAI Certified Fluid Power Accredited Instructor CFPAJPP Certified Fluid Power Authorized Job Performance Proctor CFPAJPPCC Certified Fluid Power Authorized Job Performance Proctor Connector & Conductor CFPE Certified Fluid Power Engineer CFPS Certified Fluid Power Specialist (Must Obtain CFPHS & CFPPS) CFPHS Certified Fluid Power Hydraulic Specialist CFPPS Certified Fluid Power Pneumatic Specialist CFPECS Certified Fluid Power Electronic Controls Specialist CFPMT Certified Fluid Power Master Technician (Must Obtain CFPIHT, CFPMHT, & CFPPT) CFPIHT Certified Fluid Power Industrial Hydraulic Technician CFPMHT Certified Fluid Power Mobile Hydraulic Technician CFPPT Certified Fluid Power Pneumatic Technician CFPMM Certified Fluid Power Master Mechanic (Must Obtain CFPIHM, CFPMHM, & CFPPM) CFPIHM Certified Fluid Power Industrial Hydraulic Mechanic CFPMHM Certified Fluid Power Mobile Hydraulic Mechanic CFPPM Certified Fluid Power Pneumatic Mechanic CFPMIH Certified Fluid Power Master of Industrial Hydraulics (Must Obtain CFPIHM, CFPIHT, & CFPCC) CFPMMH Certified Fluid Power Master of Mobile Hydraulics (Must Obtain CFPMHM, CFPMHT, & CFPCC) CFPMIP Certified Fluid Power Master of Industrial Pneumatics (Must Obtain CFPPM, CFPPT, & CFPCC) CFPCC Certified Fluid Power Connector & Conductor CFPSD Fluid Power System Designer CFPMEC (In Development) Mobile Electronic Controls CFPIEC (In Development) Industrial Electronic Controls

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Tentative Certification Review Training IFPS offers onsite review training for small groups of at least 10 persons. An IFPS accredited instructor visits your company to conduct the review. Contact kpollander@ifps.org for details of the scheduled onsite reviews listed below. HYDRAULIC SPECIALIST CERTIFICATION REVIEW September 13-16, 2021 - CFC Industrial Training, Fairfield, Ohio | Written test: September 16, 2021 September 27-30, 2021 - MSOE, Milwaukee, WI | Written test: September 30, 2021 ELECTRONIC CONTROLS CERTIFICATION REVIEW August 9-12, 2021 - CFC Industrial Training, Fairfield, Ohio | Written test: August 12, 2021 CONNECTOR & CONDUCTOR CERTIFICATION REVIEW November 16-17, 2021 - CFC Industrial Training, Fairfield, Ohio | Written and JP test: November 18, 2021 MOBILE HYDRAULIC MECHANIC CERTIFICATION REVIEW Online Mobile Hydraulic Mechanic Certification Review (for written test) offered through info@cfcindustrialtraining.com. This course takes you through all chapters of the MHM Study Manual (6.5 hours) and every outcome to prepare you for the written MHM test. Members receive 20% off. (Test fees are additional - separate registration required.) August 30 - September 1, 2021 - CFC Industrial Training, Fairfield, Ohio | Written and JP test: September 2, 2021 INDUSTRIAL HYDRAULIC MECHANIC CERTIFICATION Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio INDUSTRIAL HYDRAULIC TECHNICIAN CERTIFICATION REVIEW TRAINING Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio MOBILE HYDRAULIC TECHNICIAN CERTIFICATION REVIEW TRAINING Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio PNEUMATIC TECHNICIAN and PNEUMATIC MECHANIC CERTIFICATION REVIEW TRAINING Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio JOB PERFORMANCE TRAINING Online Job Performance Review - CFC Industrial Training offers online JP Reviews, which includes stations 1-6 of the IFPS mechanic and technician job performance tests. Members may e-mail askus@ifps.org for a 20% coupon code off the list price or get the code in our Members Only area for the entire IFPS Job Performance Review; test not included. LIVE DISTANCE LEARNING JOB PERFORMANCE STATION REVIEW E-mail info@cfcindustrialtraining.com for information.

AUGUST 2021

COVER STORY

SMARTEN UP

By Kevin Sargeson, Director of Field Sales, Balluff Canada; and Anthony Haywood, Technical Writer, Balluff Inc.

he year 2021 marks a decade since the concept of Industry 4.0 was introduced at the Hannover Messe trade fair in Germany. One year later, General Electric coined the term industrial internet. The concept of Industry 4.0 was a vision at the time, and the Industrial Internet of Things (IIoT) was on the horizon. In ten short years, we have arrived in an industrial era in which smart, digitally networked hydraulic solutions are a reality. What do we mean by Industry 4.0 and IIoT, terms that are often used interchangeably? Industry 4.0 generally describes the latest industrial revolution, in which production and various processes are coordinated, integrated, and monitored by cyber-physical systems. These cyber-physical systems have computer technology at their core. Industry 4.0 is also a philosophy that embraces ongoing change, such as lean manufacturing. IIoT grew from the beginnings of late1960s automation with programmable logic controllers (PLCs) and robots. Today, the term characterizes the networking of technologies, including advanced sensors, digital drives, and other devices that lead to new process efficiencies. In fluid power, IIoT refers to smart sensor technologies that monitor temperature, pressure, flow, level, travel, and position in hydraulic cylinders. Systems share this 18

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data to provide information about hydraulic processes in real time. Additionally, they share information about components that can be analyzed and visualized to improve operations. For example, a digital drive solution using IIoT might include temperature, flow, and level monitoring, along with pressure measurement; parameterization and communication from field level to the controller via the IO-Link communications standard; a machine controller; monitoring and visualization of the data on a PC; and data analysis in the cloud. Systems that integrate smart hydraulics are used today across a wide range of industries, processes, and applications, including iron and steel, stamping in the automotive sector, the marine industry, offshore exploration and extraction in oil and gas, and offshore wind farms, among others. Smart hydraulics increases efficiency on multiple levels, beginning at the individual machine level. In the wind-energy sector, for example, intelligent systems with smart sensors adjust the blades of wind turbines to harvest the wind optimally. Magnetostrictive linear position sensors provide hydraulic cylinder piston position feedback. We also find intelligent hydraulics in control valves and hydraulic power units. Solutions such as these can be integrated

into existing or new installations to increase efficiency. This allows you to easily upgrade analog systems with classical hydraulic systems. When these pieces come together, they are more than the sum of their parts. They offer a systems-level understanding of work and work processes. Seeing the performance of individual parts can help you understand and optimize the system as a whole. Increased safety is another benefit. Ultrafast feedback motion compensation is now being integrated into gangway systems, for example, to compensate in real time for movement caused by wave or wind conditions. Reduced energy consumption is another example. Manufacturers of systems for hoisting and transferring loads use smart hydraulic systems to store energy released during lifting and transferring by harvesting the upward motion of a vessel. The smart system recovers this energy from a hydraulic accumulator when needed during the downward motion. And digital drive hydraulics can reduce material use and waste, making installations cleaner and greener. But some of the most significant benefits are in predictive maintenance based on precise condition monitoring, analysis, and modelling. Smart sensors continually acquire data, and analyze, diagnose, and visualize the condition in real time. This information is WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

used to predict either the failure of a specific component or its working life, allowing you to act before failure and increasing equipment availability. This helps you progress to a level of efficiency beyond timeframe-based preventive maintenance, such as every six months or after a certain number of actions. You can perform data-based diagnosis remotely. In an offshore wind turbine, for example, this can save significant costs and increase work safety because personnel spend less time traveling to turbines and diagnosing or repairing faults in precarious working conditions. One recent and quite unexpected benefit of IIoT occurred when the COVID-19 pandemic struck and travel to work sites was difficult. The impact was softened for teams that could rely on sensors in the field to monitor facilities remotely.

Data documentation in the cloud.

Machine controller.

Monitoring and visualization.

Autonomous axis in the field level.

Designing a smart system Designing an IIoT-based system is a way of reckoning with your future needs. To meet those needs and maximize your short-term return on investment, consider several factors. First, determine the parameters of the application or process so you can select the best IIoT components. Make decisions about the type of information to collect, how much of it to collect, and the resources required to manage and use this information. More information is not always better because information consumes network bandwidth and the attention of the system’s users and administrators. Setting IIoT requirements early helps identify which sensors can contribute to a smart system’s goals. The devices must obviously be suitable for the process. Is the sensor sufficiently robust to withstand the cold of offshore applications in arctic conditions? Does a position sensor monitoring a hydraulic cylinder work properly when exposed to heat in the steel industry? Are heat shields or other protective measures necessary to

Valve parameterization via IO-Link. Temperature measurement. Detecting liquid flow.

Pressure measurement.

Continuous level detection. Level monitoring.

(Continued on page 20)

AUGUST 2021

are exchanged with digital signals, either generated as digital signals or converted from analog. Because they are digital signals, they resist interference and are free from noise. This makes it a strong communications basis for documentation, storage, visualization, and analysis of data downstream directly in the cloud or on an edge computing device. One of IO-Link’s many strengths is that it uses standard, unshielded three- or four-conductor cables. This lean wiring saves on the costs of installing complex and expensive cable. IO-Link can be easily integrated into systems and is manufacturer neutral. Once connected to the master, IO-Link devices are recognized and configured with little effort. If an IO-Link device is replaced, parameters can be automatically written from the IO-Link master or controller to the device, simplifying maintenance.

Further optimizing IIoT

(Continued from page 19) mitigate the effects of ambient heat through conduction, conversion, or infrared exposure? Will sensors be exposed to liquids such as coolants, oil, and water, and do they have the ingress rating required for the task? Heat, cold, physical impact, shock, vibration, liquid ingress, the presence of corrosive chemicals, and high cylinder pressure are other factors to consider. Sensor testing, according to IEC 60068-2, the international standard for the environmental testing of electromechanical products, offers good orientation. Building redundant sensors or redundant outputs into a process can also mitigate the effects of potential malfunction in extreme environments, allowing you to realize the benefits of predictive maintenance.

IO-Link All of this data must be processed and analyzed somewhere. It might be in the control unit, edge computing close to the sources of the data, or computers in the cloud. The method is generally determined by data rates, the volume of data, scalability to allow for increases in data volume, latency (delay times in the network), privacy and security, reliability, and, of course, cost. Consider the potential failure modes. For example, external 20

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connectivity problems may arise that could make remote monitoring challenging. System complexity can be an added challenge since complexity can require more training or more staffing. A large number of legacy devices – as is often the case in process industries – require the ability to integrate analog equipment into IIoT efficiently. This is possible with IO-Link, for example. One way to reduce the complexity of your system is to use sensors built on the IO-Link protocol. IO-Link is an international communication standard (IEC 61131-9) that has become a key enabler of IIoT. Some compare its impact in industry to the dramatic changes brought about by the PLC and automation of the late 1960s. It has provided an enormous boost to industrial automation. Because of its simplicity and universality, it can make a drive or hydraulic system IIoT-capable. IO-Link provides bidirectional, point-to-point communication between IO-Link devices located in the field (i.e., sensors and actuators) and an IO-Link master. The IO-Link master also provides the interface with the controller via existing networks or bus systems. Configuration and diagnostics can therefore be performed from a central location. Process data about the devices and events

In 2021, 10 years on from the first tangible progress in Industry 4.0 and IIoT, we find ourselves in a rapidly developing networked industrial landscape. Components are becoming smaller, creating space that can be used to add multipurpose condition monitoring sensors to hydraulic components and processes. These can, for example, acquire and process data on vibration, relative humidity, contact temperature, and ambient pressure. The components then process this information in the sensor and transmit it via IO-Link to the host system, where it can be further analyzed, visualized, and used to create models. The sensors also detect and communicate their own condition, informing operators about their temperature, number of operating hours, and start cycles. As with other sensors, they can be parameterized easily with IO-Link. While multipurpose sensors may not replace multiple single sensors in all relevant processes, we increasingly recognize their benefits, especially in noncritical processes where they are particularly cost-effective. A great deal has been achieved in the development of smart hydraulics. But it is also a journey of shifting horizons. We can expect new gains in coming years as technologies bring us forward and our imaginations make new and better use of the information these systems provide. In this regard, we can expect smart hydraulic technologies to become smarter and deliver greater efficiencies in the future.

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A successful example of a system upgrade using state-of-the-art IIoT technologies is the Mount Coffee hydropower project, located outside Monrovia, Liberia. The plant was constructed on the St. Paul River in the late 1960s and once had a maximum capacity of 64 megawatts. It was severely damaged during the civil war of 1989-1993 and remained offline for 20 years. A critical part of the work was to upgrade its radial inlet gates, which are designed to control water level, feed water into the turbines, and, in the event of a fault, close intake.

CASE STUDY

Upgrading a Hydroelectric Power Plant

The facility has ten radial inlet gates measuring some 15 meters (49 feet) in width to control water level. Another four inlet gates control water flow into the turbines and emergency shutdown. Hydraulic drives are used for these processes.

HII

HYD-4404

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EXPERTS IN HIGH PRESSURE TESTING MOBILE

•

PORTABLE

• Hydrostatic Pressure Testing • Bolt Tensioning & Nut Torquing • Chemical Injection • Charging of N2 Accumulators • Leak Testing • Fluid Measuring Systems

• Clamping • Valve Actuation • Calibration • Gas Transfer • Coolant Injection

Each of the modules was tested before being delivered and simply plugged in on-site. The switch boxes are connected by Profibus DP to the control level. An event warning is provided in case of a disturbance, allowing fast remedial action. In one instance during the installation phase, a sensor hub had to be exchanged. This might have been a timeconsuming undertaking, but with IO-Link, the relevant diagnostic information was received from the sensor hub, and only one employee was required to exchange it. Today, equipped with networked hydraulic technologies, the Mount Coffee hydroelectric project supplies green power for one million people at a maximum capacity of 88 megawatts.

Mobile - Portable

HY drauli c DR AU s Inter LIC n S o ationa l, I r PN EU nc. MA TIC S

Work began on restoring and upgrading the installation in late 2016 and is now complete. The facility has been configured with two IO-Link masters in a switch box at each gate, with each of these switch boxes receiving up to 20 different signals. The data is collected from limit and position switches (inductive and conductive) as well as sensors that provide information on the movement of the radial gates. Information is also acquired from valves that control, regulate, and shut down the gates. Furthermore, various signal lamps and illuminated switches are also connected via IO-Link. Unshielded three-wire cables with M12 connectors are used. Because communication with IO-Link is bidirectional on standard cable, the amount and cost of cabling were minimized. As a result of IO-Link’s simplicity, a time savings of approximately 50% on the installation of cables could be achieved.

9201 Independence Ave., Chatsworth, CA 91311 USA (Phone) 818.407.3400 | (Fax) 818.407.3428 www.hiipumps.com

Made in the USA

AUGUST 2021

TEST YOUR SKILLS

Understanding Supply-Side

Air Preparation

As air is compressed, the temperature of the air increases significantly. The compressor discharge air temperature is typically over 200°F (93°C) for a system operating at 120 psi (830 kPa). Compressed air must be cooled from this high temperature or it would be hazardous. Various coolers are utilized to reduce the air temperature. Air compressors that have two or more stages will have an intercooler between the stages to eliminate some of the heat before the air is fed into the next stage of compression. This improves efficiency. An aftercooler is used to reduce the compressed air temperature. A properly sized aftercooler will reduce the compressed air discharge temperature from 5 to 20°F (2.7 to 11°C) above the ambient air or cooling water. On small compressors, the aftercooler may be a finned tube placed in the airstream of a fan that is an integral part of the compressor drive pulley. On larger systems the aftercooler can be either an air-to-air cooler or an air-water cooler. The aftercooler should be located as close as possible to the discharge of the air compressor(s). The air-to-air aftercooler is commonly a traditional radiator style or a plate cooler. Sizing the cooler must consider the maximum expected ambient air temperature at 100% humidity. The heated ambient air will need to be vented out of the compressor area. In the next phase of the conditioning process, the dryer or filter are typically designed to operate at 100°F (37.7°C) or less. If the cooler cannot be sized to lower the discharge air to those temperatures, an air-water cooler or other type of device should be considered. Shell and tube style aftercoolers, consisting of a series of tubes that the hot air flows through with the cooling water flowing around the outside of the tubes in the shell, are commonly used. A water modulating valve is recommended to maintain a constant water temperature and to reduce water flow. The aftercooler will need to be inspected regularly to insure that passageways remain clear. A dirty aftercooler will be less effective, allowing a higher discharge temperature and creating increased pressure drop. The higher the discharge temperature of the aftercooler, the higher the remaining water content, causing the dryer to work harder to achieve the required relative humidity.

AUGUST 2021

MAXIMUM PARTICLE SIZE PARTICLES

CLASS

By particle size (maximum number of particles per m3) See note 1 0.10-0.5 μm

0 1 2 3 4 5 6 7 8 9 X

WATER

0.5-10.0 μm

By mass

1.0-5.0 μm

mg/m3

OIL

Pressure dew point

Liquid

°C

g/m3

°F

Liquid, aerosol, vapor See note 2 mg/m3

As specified by the equipment user or supplier and more stringent than class 1 ≤400 ≤10 ≤-70 ≤-94 ≤6,000 ≤100 ≤-40 ≤-40 ≤90,000 ≤1,000 ≤-20 ≤-4 ≤10,000 ≤+3 ≤+37 ≤100,000 ≤+7 ≤+45 0 - ≤5 ≤+10 ≤+50 5 - ≤10 ≤0.5 0.5-≤5 5 - ≤10 > 10 > 10

≤20,000 (3) ≤40,000 (3) -

≤0.01 ≤0.1 ≤1 ≤5

Note 1: For Particle Class 1 and 2 (0.1-0.5 µm range only), a laser particle counter is required. Note 2: ISO 8573 Oil includes aerosol, vapor and liquid oil. Liquid oil is typically sampled when wall flow is present, contamination is suspected, or results are greater than 5 mg/m3.

WATER CONTENT OF AIR IN GALLONS PER 1,000 CUBIC FT. Temperature °F % RH 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

35 0.0019 0.0039 0.0058 0.0078 0.0098 0.0117 0.0137 0.0156 0.0176 0.0195 0.0215 0.0235 0.0254 0.0274 0.0294 0.0313 0.0333 0.0353 0.0372 0.0392

40 0.0024 0.0047 0.0071 0.0095 0.0119 0.0143 0.0166 0.0190 0.0214 0.0238 0.0262 0.0286 0.0310 0.0334 0.0358 0.0382 0.0406 0.0430 0.0454 0.0478

50 0.0035 0.0069 0.0104 0.0139 0.0174 0.0209 0.0244 0.0279 0.0314 0.0349 0.0384 0.0419 0.0454 0.0490 0.0525 0.0560 0.0596 0.0631 0.0666 0.0702

60 0.0050 0.0100 0.0150 0.0200 0.0251 0.0301 0.0351 0.0402 0.0453 0.0503 0.0554 0.0605 0.0656 0.0707 0.0758 0.0810 0.0861 0.0913 0.0964 0.1016

70 0.0071 0.0142 0.0213 0.0284 0.0356 0.0427 0.0499 0.0571 0.0644 0.0716 0.0789 0.0861 0.0934 0.1007 0.1081 0.1154 0.1228 0.1302 0.1376 0.1450

80 0.0099 0.0198 0.0298 0.0398 0.0498 0.0599 0.0700 0.0801 0.0903 0.1005 0.1107 0.1210 0.1313 0.1417 0.1521 0.1625 0.1730 0.1835 0.1940 0.2046

90 0.0136 0.0273 0.0411 0.0549 0.0689 0.0828 0.0969 0.1110 0.1251 0.1394 0.1537 0.1681 0.1825 0.1970 0.2116 0.2263 0.2410 0.2559 0.2707 0.2857

100 0.0186 0.0372 0.0561 0.0750 0.0940 0.1132 0.1325 0.1519 0.1715 0.1912 0.2110 0.2310 0.2511 0.2713 0.2917 0.3122 0.3328 0.3536 0.3745 0.3956

110 0.0250 0.0501 0.0755 0.1012 0.1270 0.1531 0.1794 0.2060 0.2328 0.2598 0.2871 0.3146 0.3424 0.3705 0.3988 0.4273 0.4562 0.4853 0.5147 0.5443

120 0.0332 0.0668 0.1007 0.1351 0.1699 0.2051 0.2407 0.2768 0.3133 0.3502 0.3876 0.4254 0.4637 0.5025 0.5418 0.5816 0.6219 0.6627 0.7041 0.7460

Water removal As the compressed air is cooled, the excess water vapor will precipitate out, along with small particulates and residual oil from the compressor. The aftercooler, filters, receiver, and additional dryers will have a sump to collect all the condensate. The condensate is primarily water, but because it will also contain particulate contaminants from the free air and residual lubrication oils from the compressor, it cannot be simply drained into a waste-water drain without additional treatment. The sumps

will need to be drained periodically to insure proper operation. The simplest drain is a ball valve that maintenance personnel periodically open to collect the condensate for disposal. For systems that have cyclical demand or require frequent draining, an automatic drain can be used. Automatic drains can be simple float valves that open when the sump fills to a preset level, have electrical sensors that open a solenoid valve or use a timer to open on a regular interval, or operate based on air compressor cycle time. WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

Drain valves will also be required in drop legs throughout the air-supply piping. Sophisticated drain valves are designed to reduce or eliminate air loss during the draining process. Due to the content of the condensate, the drain valves will need to have screens or filters to prevent the condensate from clogging the control orifices and preventing proper operation. The collected condensate must be disposed of in accordance with federal, state, and local environmental regulations. The amount of condensate that must be disposed of in this manner can be reduced by using an approved oil/water separator. When updating or replacing existing drains, zero loss drains should be used.

TEST YOUR SKILLS

Which one of the following components removes the most water from compressed air? a. Intercooler. b. Aftercooler. c. Receiver. d. First stage. e. Inlet filter.

What is the ISO 8573-1 recommended dew point for class 3 air? a. 37.4% relative humidity. b. -40°F (-43°C). c. 5°. d. 68°F (20°C) and 60% relative humidity. e. -4°F (-20°C).

See page 31 for the solutions.

Oil/water separators The simplest separator is a gravitational separator that consists of a settling tank. The lighter free oil is skimmed off the top and the water is drained off the bottom. If the oil is emulsified in the water, as in the case with some synthetic oils, the water will still contain residual oil. Other types of separators will utilize chemical absorption of the oils while repelling the water. These will also tend to collect the particulate contaminants. Since the oil bonds to the media, the media will need to be replaced on a regular basis. Mechanical separators use coalescing and tortuous path methods to initially separate the oils and may have additional activated charcoal elements to remove oils not separated by the coalescer. Periodic maintenance of the oil/water separator will include changing the elements periodically and cleaning the settling tank to remove residual sludge. Disposal of any condensate as well as filter elements must be in accordance with federal, state, and local environmental regulations. Relative humidity is defined as the amount of water vapor present in air, expressed as a percentage of the amount needed for saturation at the same temperature. Dew point is the saturation temperature for water vapor in air. If a sample of air is kept at a fixed pressure, but the temperature is reduced, when the temperature reaches the dew point, any additional cooling that occurs after the compressor and before the point of use may cause additional water to precipitate out of the air. The water will act as a contaminant, mixing with lubricating fluids, causing rust and sludge to form that will plug orifices and cause valves and actuators to stick and malfunction. For this reason, additional dryers may be required, after the air leaves the compressor room receiver, just before the final point of use. 

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AUGUST 2021

OTC Resumes In-Person Event with Virtual Components HYBRID 2021

AUGUST 2021

After canceling its annual trade show last year due to the COVID-19 pandemic and then postponing it in May, the Offshore Technology Conference returns this month with a hybrid in-person and virtual event Aug. 16-19 at Houston’s NRG Park. The gathering of energy-industry professionals will follow guidelines to protect against COVID, including social distancing, daily health and temperature screening, and enhanced cleaning and disinfection. OTC is also eliminating open food-service options wherever possible.

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Masks are optional. Texas lifted its mandatory mask requirement in March. With more than 564,000 square feet of exhibit space and over 2,000 providers of products and services, the conference expects more than 59,000 energy professionals from over 100 countries. Several awards will be handed out, including Spotlight on New Technology, an award for exhibitors that showcases advanced technologies. The conference also gives awards for distinguished achievement and emerging leaders. OTC’s Around the World Series connects attendees with global government leaders and energy executives on topics such as emission reduction, energy policies, and recent discoveries. A technical program presents offshore energy scientists, engineers, researchers, and executive-level speakers who discuss best practices, technical innovations, and emerging trends.

For more information, visit https://2021.otcnet.org/.

Fluid Power Exhibitors Accumulators Inc................. 2547 Additel................................... 1413 American Alloy Steel............ 2511 AMETEK................................ 2306 Ashcroft................................. 1017 Bauer Compressors............... 841 Bosch Rexroth Corporation.1207 Brennan Industries............... 1501 Doering.................................... 604 Dynex/Rivett............................ 601

Engineered Specialty Products............................. 2169 ESI, Inc............................... 2356 Faster..................................... 3154 GW Lisk................................. 2666 GP:50..................................... 2164 Hydradyne............................. 3100 Hydraquip.............................. 2041 Innovative Fluid Power......... 2822 Innovative Hydraulics........... 2760

Lee Company, The................. 941 Mako Products................... 2647 McCrometer.......................... 2257 Motion Industries................. 3735 Orion Instruments................... 563 PacSeal Hydraulics............... 2110 PBM Inc. Valve Solutions..... 2710 Pneumatic and Hydraulic..... 2305 Sauer Compressors USA..... 1907 Schneider Electric................. 1517

Senior Metal Bellows............ 2204 SIKA USA............................... 3711 Spir Star................................. 1301 Stucchi USA.......................... 4009 Thermal Edge ....................... 1401 Tube-Mac Piping Technologies...................... 2746 Wilkes & McLean................ 3110 Winters Instruments............. 1215

Advertisers are marked in bold.

Keynote Speaker Presentations Monday

Wednesday

• Egina Development, Technological Expertise and Local Commitment • Offshore Oil and Gas Industry Transformation and Smart Technologies

• A n Overview of Projects and Innovations in Equinor’s New Offshore Investment Cycle • The Journey to Net-Zero-Emissions: Challenges and Actors

Tuesday

• The Role of Technology in Advancing the Energy Transition • Digitalization in the Oil and Gas Industry

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Thursday

• Center for Offshore Safety: SEMS Leadership Presentation • Offshore Aquaculture • Center for Offshore Safety: Safety and Environmental Management Regulatory Perspective

AUGUST 2021

Run-Time Monitor Racks Up the Miles From Webtec too many years ago, the only status indicators in automobiles were a coolant temperature gauge, a voltage or battery charge indicator, a speedometer, and an oil-pressure gauge. Today we can also monitor engine speed and diagnostics, brake pad condition, tire pressure, fuel consumption, air-bag condition, seat-belt usage, windshield-washer level, the progress toward a destination, among other parameters. But some components remain difficult or impractical to monitor, such as the state of the camshaft drive belt or the condition of the brake fluid. In these cases, the component is usually “lifed,” that is, recommended for service or replacement based on the amount of time it’s been in use or the mileage as measured by the vehicle’s odometer. A similar situation exists with hydraulic systems. In the past, a hydraulic power unit’s instrumentation was a fluid thermometer, a sight glass, and a pressure gauge. If the system was relatively new, the pressure gauge may have worked, 26

AUGUST 2021

but often its needle would sit at the bottom of the dial, the victim of pressure spikes or mechanical vibration. Today we can reliably monitor not only system pressure and pressure transients but also the flow rate, temperature, cleanliness, and water content of the fluid, plus component vibration and efficiency. As industrial and mobile machinery has become increasingly sophisticated, such predictive maintenance components are more readily available and cost effective as well as necessary. An excavator standing idle due to a burst hose or an unforeseen pump failure on an injection molding machine could be costing thousands of dollars per hour in lost production alone. Unexpected component failures are costly, potentially dangerous, and can pollute the environment. But some hydraulic components are difficult to monitor effectively. Flexible hose condition is one example. Although at least one manufacturer’s product can now monitor hose condition, it is still far from available for all hose applications. As a result, manufacturers recommend changing

hydraulic hoses, filters, air breathers, dynamic cylinder seals, and other parts after specified periods of time or usage. Although the passage of time is easily established, machine usage is not always easily monitored. For a process machine operating continuously for two or three shifts a day, usage can be predicted reasonably accurately. But that’s not the case with a piece of farm or construction machinery that is used intermittently or seasonally. In other words, in most cases, hydraulic systems still lack the equivalent of a vehicle’s odometer. Webtec’s RFS200 run-time monitor remedies that situation. The unit’s principle of operation is a variable orifice flow meter and a magnetic switch that senses the position of a piston. Sensing flow rather than pressure means that trapped pressure or pressure created by reactive loads (or thermal expansion) when the system is shut down cannot generate a false usage reading. The unit can be installed in any part of the hydraulic system and can operate with pressures up to 6,000 psi (420 bar). Flow rates up to 52 gpm (200 lpm) WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

can pass through the unit with minimal flow resistance. For example, with a forward flow rate of 52 gpm (200 lpm) the pressure drop through the unit is typically less than 45 psi (3 bar). It is also possible to direct reverse flow through the unit, although counting does not occur in the reverse flow direction. The unit is suitable for hydraulic mineral oil to ISO 11158 category HM, with an operating fluid temperature range from -4°F to 212°F (-20°C to 100°C). Timer accuracy is ±0.2% over the specified temperature range. Different port connection sizes and thread forms are available to match with customer requirements. The unit should be mounted horizontally and not installed immediately adjacent to components generating high magnetic fields, such as an electric motor. It should be protected by at least a 40-micron filter in the hydraulic circuit, and oil cleanliness should be maintained better than NAS 8 or ISO 19/17/14. There are two M6 holes for bulkhead mounting, but they should not be used to support pipework. Flexible hoses connected to the unit should be clamped to minimize flexing stress at the threaded ports. Needless to say, all connections should be made by suitably trained personnel. The unit is preset so that counting initiates when flow through the unit exceeds 2.6 gpm (10 lpm). This trigger point is unaffected by pressure but may vary slightly with fluid viscosity; higher viscosities decrease the switching flow, and lower viscosities increase it. On reaching the trigger point, a blinking decimal point on the LCD display indicates that the counter is operational, and counting accumulates while the flow rate remains above the trigger point. Being battery operated (with sensitive components protected to IP66), the unit requires no external power supply, and battery life is at least 10 years. There’s no reset function on the unit, so it is effectively tamper-proof, although the unit could obviously be replaced if someone was determined to falsify run-time data. The data output is a visual readout, but options such as an IoT cellular connection for remote data acquisition could be added. Initially the product was market driven following a request from a customer manufacturing hydraulic attachments in the agricultural sector. Many such attachments are shared by co-operatives, so a foolproof way of charging customers by usage was required. Another customer in the construction-machine business needed to monitor usage for each attachment to determine an appropriate maintenance schedule. Attachments can be changed up to 30 times a day, and keeping track of their usage any other way would be very difficult. WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

In the industrial sector, applications requiring high flow rates of fluid often use multiple pump systems in which individual pumps are brought online at the appropriate time in the machine’s flow cycle. In some cases, additional pumps may be reserved as standby units used only in the event of the failure of a normal-duty pump. Such arrangements are common in process industries such as steelworks, where a malfunction of the hydraulic system would cause major problems. Keeping track of each pump’s usage would be a significant benefit in planning a scheduled maintenance program for pump overhaul or replacement. The information could also be used to even out the run time of all the pumps in a system, although one school of thought says this is not always the correct approach, since all pumps then approach the end of their useful life at approximately the same time. But by having the relevant usage data for each pump, the maintenance engineer can at least make the most appropriate decision about how the pumps are used. For fixed-displacement pump systems using unloading valves, the unit could be installed on the system side of the unloading valve to record

only the time that the pump is delivering flow at full pressure, rather than the unloaded periods when minimal wear is likely to take place. Alternatively, the unit could be installed on the pump side of the unloading valve, in which case it would record the total pump run time both on and off load. A maintenance engineer or end customer can make the choice. The condition of hydraulic motors is not always easy to establish using onboard diagnostic sensors, so in applications where they operate for long periods, (such as mixer, shredder, or conveyor drives) the customer can establish a usage-based replacement or overhaul schedule using data provided by a run-time monitor. Component test rigs may also be an application in which the unit may prove useful. Endurance testing often involves operating or cycling components for hundreds or thousands of hours, so the unit’s capabilities to accurately record up to almost 10 million hours of operation cover most requirements. 

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• BSPP • BSPT • C/S & 316-Stainless • Aluminum • Copper-Nickel

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SPECIAL AD SECTION

PRODUCT SPOTLIGHT

Suppressor

Accumulators

Hydraulic Noise and Shock Suppressor Introducing—9S Series Investment Cast Swivels The "9S" Series swivels represent one of the most complete range of sizes and configurations available to industry. This series has been redesigned to incorporate a one-piece barrel arrangement, thus eliminating the need for braze joints. These swivels are pressure balanced with operating pressures up to 5,000 psi. All configurations are designed with a 4:1 Safety Factor and include RoHS compliant zinc plating. P.O. Box 6479 • Fort Worth, TX 76115 V. 817/923-1965 • www.hydraulicsinc.com

Wilkes and McLean manufactures an In Line Noise and Shock Suppressor for hydraulics and is a stocking distributor of Nacol Accumulators. Our suppressors eliminate pulsations, which greatly reduces noise and vibration from applications from a few gallons up to 200 gallons. We stock all of our suppressor sizes as well as Nacol Accumulators and parts from 1/5 of a pint up to 15 gallons, in our Schaumburg, Illinois facility. 877.534.6445 info@wilkesandmclean.com www.wilkesandmclean.com

Liquid Level Switches

Go ahead. Push me. Ordinary heavy duty not heavy enough? Heavy-Duty Mill Cylinders for: • Induction-Hardened, Chrome-Plated Rods • Heavy Wall Tubing • Replaceable Glands & Retainer Rings • High-Load Piston Design Think indestructible and call Yates. www.yatesind.com

AUGUST 2021

Yates Industries (HQ) 586.778.7680 Yates Cylinders Alabama 256.351.8081 Yates Cylinders Georgia 678.355.2240 Yates Cylinders Ohio 513.217.6777

Liquid Level Switches are designed to shut down machinery or turn on warning devices when liquid supply recedes to a predetermined level. They can be wired to flash warning lights, sound howlers, shut down machines, or signal computers. This is especially helpful in unattended automated plants. Available with a housing for external mounting or without housing for internal applications. Oil-Rite Corporation PO Box 1207 Manitwoc WI 54221-1207 Phone: (920) 682-6173 Email: sales@oilrite.com www.oilrite.com

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SPECIAL AD SECTION

FluiDyne Fluid Power Stocks A4V Piston Pumps & Parts

Superlok Zero Leak Technology Tube Fittings Superlok tube fittings are equipped with the industry’s only built-in gap gauge. During installation, the compression nut is simply tightened until the gap gauge rings pop off. This is the point of perfect compression and seal, which provides an added level of safety and accuracy for companies worldwide. Superlok’s patented innovation ends leaks that are caused by improper tightening procedures.

FluiDyne carries a complete line of A4V piston pumps that are available in displacement of: 40, 71, 125, 180, 250. Our units are used in many different applications: agriculture, forestry machinery, construction, on-highway, commercial vehicles, offshore, marine, wind/ocean energy, automotive and more. Controls include: DR, DRG, FR, FRG, DFR, and LR2. They are available in SAE or metric. The versatile A4V units carry the industry leading 18 month warranty. Units are fully tested, documented and guaranteed to perform 100% to the original manufacturer’s specification. Call, email, chat…we’re ready to help!

Superlokworld.com OTC Booth #2647 HYBRID 2021

586.296.7200 • sales@fluidynefp.com www.fluidynefp.com

P RO D U C T R E V I E W

Piab Conveyor Gently Transports Fragile Foods » PIAB’S piFLOWt CONVEYOR is dedicated to the gentle handling of delicate ingredients and products. Suitable for transporting up to four million items per hour, the piFLOWt conveyor can gently transport fragile foods between processing units, such as tablet presses, coating drums, and packaging lines, avoiding all risks of damage. At the core of piFLOWt is the proprietary piGENTLE, an innovative patent pending technology that maintains a gentle flow by regulating the

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feed pressure of the pump, ensuring that fragile ingredients or products are handled delicately. piFLOWt is an extension to Piab’s range of piFLOW conveyors for powder and bulk materials and was developed to meet the stringent demands regarding operational safety and hygiene within the food (piFLOWf), pharmaceutical (piFLOWp), and chemical (piFLOWi) industries. For more information, visit www.piab.com/.

AUGUST 2021

Web Marketplace

www.inserta.com www.adaconn.com Adaconn® + Inserta® offer a variety of components including flange adapters and connectors, ball valves, check valves, pressure controls, and modular fittings that can be used to make smartly designed compact hydraulic systems. A large inventory of finished components allows most standard items to ship from stock. Custom components and assemblies are available.

Visit our website to learn more about our expanding product offerings.

www.genericslides.com GENERIC SLIDES provides linear positioning devices utilizing combinations of tried and proven features. We supply the smooth and accurate, single axis, and multiple axis stages, x-y tables, and robust, heavy duty, slide systems. Specializing in stainless steel, aluminum, or steel assemblies, our many offthe-shelf, slides, options, and custom design service, provides you with application specific, solutions, and reasonable deliveries. 1049 William Flynn Highway, Glenshaw PA 15116 sales@genericslides.com (412) 492-7272

AUGUST 2021

SPECIAL AD SECTION

www.festo.com More productive and efficient all round. The Festo Motion Terminal really comes into its own in pneumatic regulation of motion, pressure and flow rate. The benefits of this digitalisation are found in all stages of the value chain, and for OEMs as well as for end users. Get ready to be inspired!

1-800-463-3786

www.flangelock.com The FlangeLock™ Tool is the ultimate contamination control tool for protecting your hydraulic systems. It allows for the simple sealing of open SAE code 61, 62 & CAT-Style hydraulic flanges without tools. Constructed from lightweight aluminum. Easy on, easy off. Offers a leakproof solution to hydraulic system and environmental cleanliness. FlangeLock™ Tools stop the mess!

Have a Purchase Order? Please email to sales@flangelock.com or fax to 203-622-1238

www.hiigroup.com HYDRAULICS INTERNATIONAL, INC. • CIRCLE 122

No Compromise on Quality or Performance Established in 1976 and headquartered in Chatsworth, California, Hydraulics International, Inc. (HII) is a leading provider of pneumatically driven hydraulic pumps, portable and skid mounted high pressure hydrostatic test units and accumulator charging units on a global basis. Since inception, HII has maintained an intense focus on design and engineering, striving to stay at the forefront of fluid power technological advances. Proudly made in the USA. When reliability counts, depend on the strength of a leader…HII, the leading name in high pressure pumps and gas boosters.

www.mainmanufacturing.com Main's website provides quick access to the 120 page catalog that includes popular styles of MAIN Manufacturing’s extensive offering of carbon and stainless Hydraulic Flanges and Components – ready for immediate shipment. Metric ordering information, weld specs, and dimensional information included. The “Quick Reference Guide” helps specify less popular items often stocked or quickly manufactured (generally 3-4 days) at our US plant. “Create-AFlange” offers more parts than the catalog — by picture. If it’s not here, or for questions, E-mails may be sent to get your answer quickly. 1-800-521-7918 info@mainmfg.com

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CL ASSIFIEDS

WANTED SURPLUS

IN STOCK FROM 25MM TO 80MM

Pumps · Motors · Valves · Servo/Proportional

MANY COVERS IN STOCK • Pressure, Flow, Directional • Large Flow 90° Valves

almomanifold.com

• Single DIN blocks • Active Valves • Monitored Poppets

Phone: 989.984.0800 Toll Free: 1.877.ALMO. NOW Fax: 989.984.0830

Email, call or fax with a list of your Surplus. We’ll provide you with a price offer! 1-800-422-4279 | 586-949-4240 Fax: 586-949-5302 | surplus@hydraulex.com

The correct answers to Test Your Skills on page 22 are 1.b and 2.e.

HIGH FLOW PROPORTIONAL FLOW CONTROL • 16MM to 50mm • Standard ISO 7368 and DIN 24342 cavity • High performance 5,000 psi • On board amplifier • 0-10 volt command

almomanifold.com

Phone: 989.984.0800 Toll Free: 1.877.ALMO. NOW Fax: 989.984.0830

HYDRAULIC FLANGES and COMPONENTS THE “SPECIAL” YOU WANT IS PROBABLY ON OUR SHELVES MAIN Mfg. Products, Inc. 800.521.7918 fax 810.953.1385 www.MAINMFG.com/fpj

ADVERTISER INDEX Company..................................................................Page.......................................................Phone................................................................................... Website Almo Manifold & Tool Co............................................... 31.............................................. 1-877-ALMO.NOW ............................................................. www.almomanifold.com CFC Industrial Training.................................................. 12.................................................. 1-513-874-3225................................................................cfcindustrialtraining.com Festo Corp...................................................................... Back Cover, 30............................. 1-800-993-3786...................................................................................www.festo.us Flange Lock.................................................................... 3, 30................................................. 203-861-9400...................................................................... www.flangelock.com Fluid Design Products, Inc............................................. 27.................................................. 1-800-774-7554...................................................... www.fluiddesignproducts.com Fluidyne Fluid Power...................................................... 23, 29, 31......................................... 586-296-7200....................................................................... www.fluidynefp.com Generic Slides................................................................ 3, 30................................................. 412-492-7272................................................................. www.genericslides.com Hydraulex........................................................................ 31.................................................. 1-800-323-8416........................................................................www.hydraulex.com Hydraulics International Inc.......................................... 21, 30............................................... 818-407-3400........................................................................ www.hiipumps.com Hydraulics, Inc................................................................ 15..................................................... 817-923-1965..................................................................www.hydraulicsinc.com IMI/Norgren………………………………………………...................... Inside Front Cover....................... 1-800-514-0129...........................................................................www.norgren.com Inserta Products............................................................. 5, 30................................................. 215-643-0192 ........................................................................... www.inserta.com Lubriplate, Inc................................................................. Inside Back Cover........................ 1-800-733-4755........................................................................ www.lubriplate.com Main Manufacturing Products Inc................................ 30, 31............................................ 1-800-521-7918...................................................................www.mainmfg.com/fpj MAKO Products.............................................................. 14, 29 ........................................... 1-405-509-2665................................................................ www.superlokworld.com Oil-Rite Corp................................................................... 28..................................................... 920-682-6173.............................................................................. www.oilrite.com Suco Technologies Inc................................................... 5.................................................... 1-800-473-7313....................................................................... www.suco-tech.com Wilkes & McLean Ltd..................................................... 15, 28............................................... 877-534-6445...........................................................www.wilkesandmclean.com Yates Industries Inc....................................................... 1, 28................................................. 586-778-7680..........................................................................www.yatesind.com

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AUGUST 2021

SUBSCRIBE BY MAIL FILL OUT THIS CARD COMPLETELY, DETACH, AND MAIL OR FAX IT TO START YOUR SUBSCRIPTION MAIL TO: PO BOX 2548 • ORLANDO, FL 32802-9830 • FAX: 1-866-207-1450 YOU CAN ALSO SUBSCRIBE ONLINE AT WWW.FLUIDPOWERJOURNAL.COM. 01  YES! Please start/continue my complimentary subscription to the Fluid Power Journal Signature (required)

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2. What is your primary job title? (check only one) 10  Administration: Chairman, President, V.P., Secretary, Treasury, General Manager, Owner, Business Manager, Director, etc. 11  Plant Operations: VP of Manufacturing/ Operation/ Production, Plant Management/ Director/ Manager/ Supervisor/ Superintendent/ Foreman/ Safety Director, etc. 12  Engineering: V.P. Eng., Eng., Design Eng., Director of Eng., Staff Specialist, Chief Eng., Senior Eng., Maintenance/Production Eng., etc. 13  Technical: Chief Tech., Fluid Power Tech., etc. 14  Mechanical: Chief Master Mech., Master Mech., Fluid Power Mech., etc. 15  Purchasing: VP/Director of Purch., Procurement Manager, Buyer, Purch., etc. 16  Other: (please specify)_________________________________________________________________________________________________ 3. Number of employees at this location? A  1-19 B  20-49 C  50-99

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4. What is the primary business activity at this location? In the Fluid Power Industry, Outside the Fluid Power Industry 56  Manufacturer 57  Distributor 58  Education 59  Original Equipment Manufacturer (OEM) 61  Other: (please specify)__________________________________________ 5. Which of the following best describes your market focus? A  Aerospace A  Marine & Offshore Equipment B  Agricultural Machinery B  Material Handling Equipment C  Automotive C  Mining Machinery D  Civil Engineering D  Packaging Machinery E  Cranes E  Plastic Machinery F  Drills & Drilling Equip. F  Presses & Foundry G  Flame Cutting/Welding Equip. G  Railroad Machinery H  Food Machinery H  Road Construct/Maint. Equip. I  Forestry I  Simulators & Test Equipment J  Furnaces J  Snow Vehicles, Ski Lifts K  Gas & Oilfield Machinery K  Steel Plants & Rolling Mills L  Heavy Construction & Equip. L  Truck & Bus Industry M  Military Vehicles M  Textile Machinery N  Construction & Utility Equip. N  Woodworking Machines O  Machine Tools O  Other (specify)_____________ P  Government Related P  Fluid Power Industry

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WE’VE BEEN SOLVING INDUSTRY’S TOUGHEST LUBRICATION PROBLEMS FOR OVER 150 YEARS...

David Roberts

Lubriplate District Manager TN, AL, GA & Northern FL

WHAT CAN WE

DO FOR YOU? WE ARE HERE TO HELP Lubriplate has been helping industry meet its lubrication needs for more than 150 years. In that time, we have learned what works and what doesn’t. Put our experience and knowledge to work for you.

WE HAVE THE PRODUCTS Lubriplate offers a full range of ultra high-performance synthetic and petroleumbased lubricants that have been engineered from the ground up to provide a number of cost saving benefits including; extended lubrication intervals, reduced friction, multiple application capability and lubricant inventory consolidation.

WE HAVE THE SERVICES Lubriplate offers its Complimentary ESP Extra Services Package to all of its customers at no additional charge. Services include; Complete Plant Surveys to help determine your exact lubrication needs, Color Coded Lube Charts and Machinery Tags which simplify maintenance procedures, Lubrication Training Programs and Follow-Up Oil Analysis.

Call 800-733-4755 to get started. INCLUDED AT NO ADDITIONAL CHARGE

Lubriplate’s

ESP

Complimentary Extra Services Package

Newark, NJ 07105 / Toledo, OH 43605 / 800-733-4755 To learn more visit us at: www.lubriplate.com

COLOR CODED LUBE CHARTS & MACHINERY TAGS PLANT SURVEYS / TECH SUPPORT / TRAINING LUBRICATION SOFTWARE / FOLLOW-UP OIL ANALYSIS

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Fluid Power Journal August 2021

Articles inside

A Primer on Mobile Fluid Power

Cover Story

Offshore Technology Conference

Test Your Skills