Fluid Power Journal May 2022 by Innovative Designs & Publishing, Inc.

MAY 2022

HYDRAULIC TURBINES GENERATE GREEN ENERGY P. 10

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The OTC Issue OTC Gathers in Houston P. 6

CASE STUDY: Seaworthy Cylinders Innovative Designs & Publishing • 3245 Freemansburg Avenue • Palmer, PA 18045-7118

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IN THIS ISSUE

MAY 2022

VOLUME 29 • ISSUE 5

Features

6 OTC Returns to Its Usual Time in May Offshore sector professionals meet in Houston for the annual trade show. 8 Case Study: Building Seaworthy Hydraulic Cylinders The project concerned a vessel in a brutal environment off the coast of West Africa.

10 Cover Story Winds of Change: Hydraulic Turbines Generate Green Energy About half of all rotors run on some form of hydraulic system. 12 The Odd Couple: A Component that Floats Your Boat A quick disconnect coupler became a go-to component for manufacturers of hydraulic boat lifts. 20 Test Your Skills Types and Applications of Compressors

Departments 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.

CELEBRATING 60 YEARS

Notable Words

Figure It Out

NFPA Update

IFPS Update

Product Spotlight

Web Marketplace

All About Vacuum

Classifieds

N OTA B L E WO R D S

The Value of IFPS Certification By Donna Pollander, ACA, Executive Director, International Fluid Power Society

BUSINESS GROWTH AND success rely on a workforce with the right skills, in the right place, at the right time. Fluid power requires skilled professionals who understand the importance of standards and the proper design, implementation, and maintenance of the equipment they work on. The industry thrives not only on technological improvements but on skills, knowledge, and professionalism – and that is what makes our industry flourish and the job more fulfilling for workers. In a world where competition for jobs and higher salaries is rising, certification offers promise because it is a credible, third-party assessment of one's skill and knowledge of a given subject. Incorporating certification from the International Fluid Power Society into your workplace means introducing consistent, measurable, and industry-recognized standards. Certification in general offers employees a sense of pride in their performance; it gives them confidence to handle challenging situations, and it builds a commitment to their profession. For an employer, that pride and confidence result in superior customer service and safety that is almost immeasurable. I FPS certification demonstrates independent confirmation of an employee’s abilities and skills. It’s a measure of an employee’s capability to design, sell, troubleshoot, and repair systems. This in-house ability means less money and time spent on downtime or hiring outsiders to do it for you. Employers who support an employee’s certification journey agree that it inspires high standards among their colleagues and distinguishes dedicated professionals within the company. In looking around your own circles, you'll likely see that your certified peers are more dedicated to their jobs, serious about their careers, and have plans to continue developing and growing in the industry. A study conducted by Work Institute found that “escalating competition for workers and a shrinking workforce are coming together, intensifying an employee-in-control marketplace.” The study indicated that it costs as much as 33% of a worker’s annual salary to replace them, and that the main reason workers leave a company is career development (22%) followed by work-life balance (12%). Indirect costs included "lost institutional knowledge, the time lag it takes to find a replacement, and the time it takes for that new worker to become fully productive." This helps to put the cost of paying for an employee's certification into perspective. Supporting and paying for an employee's certification yields measurable dividends to an employer. There are many reasons an employee may want professional certification: personal sense of achievement, an increase in salary or status, promotion, or specialized expertise with a view to career development. But it's not just the employee who benefits

MAY 2022

from professional certification; employers profit too in more ways than you might think. Happy employees present a more credible face to clients, and they are happy to work for an organization with a good reputation in the industry. Increased productivity and boosted morale benefit the organization, its employees, and its clients. In a Forbes Magazine article titled "Why A Handful of Companies Leave the Rest in the Dust," Marco Annunziata comments on the widening gap between the best-performing companies and the others. “It is not that the most productive firms are investing more in equipment,” Annunziata wrote. “The key to faster productivity growth is the ability to combine new technologies with the right human capital and to change a firm's operations, processes, and managerial practices to exploit the new opportunities. Education, training, and upskilling are equally important.” Here are other reasons to support certification: • Certification increases available skills, which contributes to increased productivity, not just by certified employees but through the opportunities it gives to other staff members who learn by osmosis as well as direct knowledge sharing. • Boosted productivity results in more efficient teams and improves an organization's bottom line. • Ongoing training supports a performance-based culture. • Certified professionals create a more trustworthy face of the company to clients and customers. • Certification expands an organization's network in its field and related industries. A company can leverage its employees' skills on social and business networks to market its products and services and increase referrals, i.e., "bragging rights"! • Instead of differentiating itself from competitors in terms of price, the credibility certification offers distinguishes an organization as a leader in the industry.

Improved efficiency and reduced risk There's a famous quote by Ziglar: “What if we train them, and they leave? What if we don't, and they stay?” The latter is a frightening thought indeed! Safety, downtime, and employee satisfaction are three important reasons for a certified workforce. Competency has a direct influence on risk for an organization. Put succinctly, by investing in their people and focusing on the competency to carry out both routine and nonroutine tasks, companies build considerable resilience to risk and thus prevent, deal with, and recover from adversity.

•

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

FIGURE IT OUT

New Problem 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: Associate Publisher: Editor: Technical Editor: Director of Creative Services: Account Executive: Accounting: Circulation Manager:

Paul and Lisa Prass Bob McKinney Michael Degan Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPSD, CFPMT, CFPCC - CFPSOS LLC Erica Montes Kristy O'Brien Donna Bachman, Sarah Varano 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 2020 BOARD OF DIRECTORS President: Denis Poirier Jr., CFPAI/AJPP, CFPHS, CFPIHM, CFPCC Danfoss Power Solutions Immediate Past President: Rocky Phoenix, CFPMMH Open Loop Energy First Vice President: Scott Sardina, PE, CFPAI, CFPHS, CFPECS - Waterclock Engineering Treasurer: Jeff Hodges, CFPAI/AJPP, CFPMHM - Altec Industries Vice President Certification: James O’Halek, CFPAI/AJPP, CFPMIP, CMPMM - The Boeing Company Vice President Marketing: Chauntelle Baughman, CFPHSOneHydraulics Vice President Education: Randy Bobbitt, CFPAI, CFPHS Danfoss Power Solutions Vice President Membership: Garrett Hoisington, CFPAI/AJPP, CFPS, CFPMHM - Open Loop Energy

Press Experiences a Shock from Cylinder Retraction Cycle By Robert Sheaf, CFPAI/AJPP, CFPE, CFPS, CFPECS, CFPMT, CFPMIP, CFPMMH, CFPMIH, CFPMM, CFC Industrial Training

A FORMING PRESS developed a shock much higher than normal after a new pilot operated directional valve was installed. The user also noticed the spin-on return line filter was leaking and had to be tightened slightly every morning. When the cylinder went to extend and form the part, it seemed to work the same. But when they energized the directional valve to retract the cylinder, there was a loud bang. They made sure that the replacement valve model number was the same as the model they used originally. The flow control was adjusted to keep the cylinder from free-falling faster than the pump supply could keep the cap end full of oil. The directional valve center selection with the A port open to tank allowed leakage to the rod side to help keep the cylinder from drifting down. What could be the problem?

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DIRECTORS-AT-LARGE Stephen Blazer, CFPE, CFPS, CFPMHM, CFPIHT, CFPMHT - Altec Industries Steve Bogush, CFPAI/AJPP, CFPHS, CFPIHM - Poclain Hydraulics Cary Boozer, PE, CFPE - Motion Industries Lisa DeBenedetto, CFPS - GS Global Resources Daniel Fernandes, CFPECS, CFPS - Sun Hydraulics Brian Kenoyer, CFPHS - CemenTech Jon Rhodes, CFPAI, CFPS, CFPECS - CFC Industrial Training Mohaned Shahin, CFPS - Parker Hannifin Randy Smith, CFPHS - Northrop Grumman Ethan Stuart, CFPS, CFPECS - Wainbee Limited Brian Wheeler, CFPAI/AJPP, CFPMM, CFPMIP The Boeing Company HONORARY DIRECTORS-AT-LARGE AND EX OFFICIO Donna Pollander, ACA 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.

Solution to the March 2022 problem:

Shaft Seal Failed on New Pump

The paper mill that blew the shaft seal on the new pumps after setting the pressure to 3,400 psi (234 bar) found several small pieces of the original damaged pump lodged inside a 90° fitting on the case drain hose where it entered the reservoir top. This allowed high pressure to build in the case, and something had to give. They were lucky the pump housing did not fail. Always check the case drain line for debris if a pump fails.

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.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

MAY 2022

OTC RETURNS TO ITS USUAL TIME IN MAY A

fter postponing from May to August last year due to COVID concerns, the Offshore Technology Conference returns to its traditional meeting time in the first week of May. OTC runs May 2-5 at NRG Park in Houston, where exhibitors will display new technologies and products for the offshore sector. Despite the lifting of COVID-related restrictions, participants, whether vaccinated or not, are being encouraged to always wear a mask inside the building. They are also asked to practice social distancing when interacting with others. New at OTC this year is the OTC Energy Transition Pavilion, a meeting place for energy transition dialogue where attendees become Energy Transition Partners and showcase advances in alternative energy sources as well as solutions to decarbonize, drive sustainability, and improve energy efficiency. The industry faces mounting investor pressure to deliver sustainable operations and reduce carbon emissions, and it has been estimated that achieving net zero will require an investment of $ 5 trillion. At OTC, companies highlight equipment, digital solutions, and process improvements that move the needle on progress toward a lower-carbon industry. They share expertise in improving efficiencies in drilling; production and operations; health, safety, and environment practices; and innovative uses of data and systems.

For more information, visit https://2022.otcnet.org/welcome.

FLUID POWER EXHIBITORS Accumulators, Inc. Alfagomma, S. p. A. Bauer Compressors Blue Ribbon Sales/Service Bosch-Rexroth Corp. Bonfiglioli USA Brennan Industries CEJN North America Custom Hydraulic Equipment Co. Elite Seals, Inc. Fruedenberg Sealing Technologies Gates Corp. GP: 50 G.W. Lisk Co. HAWE Industries High Pressure Equipment Co. Hydradyne LLC Hydraquip Hydraulics International, Inc. Hy-Lok USA Innovative Fluid Power Innovative Hydraulics, LLC Kracht Corp. MFP Seals Motion Industries MW Components NRP-Jones LLC PacSeal Hydraulics Parker Hannifin Corp. Pneumatic & Hydraulic Co., LLC Quaker Houghton Rotor Clip Sauer Compressors USA SFP Hydraulics, Inc. Smalley Corp. Spir Star Ltd. Stucchi USA, Inc. Superior/MAKO Products The Lee Company Tube-Mac Piping Technologies Ltd. Wilkes & McLean

KEYNOTE SPEAKERS 3917 3043 823 3108 2306 3157 3018 1302 774 1278 3017 3707 3108 865 1101 1502 2300 2010 1807 2002 3365 2770 2266 2507 3273 3411 1317 2007 2614 3067 2701 329 3023 2680 1703 902 3107 364 1735 810 2376

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Monday • The Role of Resilient Hydrocarbons on the Path to Net Zero: bp’s Perspective from the Gulf of Mexico • Sustainability and Energy Transition: The Road to Net Zero

Tuesday

ONSITE TRAINING

AND CERTIFICATION FOR: Hydraulic Techs & Engineers Electrical Techs & Engineers Pneumatic Techs & Engineers Multicraft Techs & Engineers

• Collision Space: Air-Sea Interactions and the Intersections between Weather, Climate, and Technology • An Evolving Energy Company: How CCS Fits

Wednesday • Alternate Energies: Hydrogen Impact and Economics • Business Ethics and Professional Conduct in International Offshore Operations

Thursday • Shaping the Future: Offshore Wind Growth in the United States • Hydrogen: The Green Fuel of the Future • Center for Offshore Safety: Managing the Knowledge Transition: Navigating Cultural Differences between Generations to Accomplish Critical Knowledge Transfer • Center for Offshore Safety: Perspectives on Safety, Safety Management, and Offshore Policy Updates from Regulatory Senior Leadership

UPSKILL YOUR WORKFORCE! CFC provides direct, Industry and/or Machine-specific training to companies the world over. Our Hands-On Training Equipment is mobilized directly to your facility with Certified Instructors traveling on-site. This turnkey approach includes all books, materials, equipment, and travel arrangements. We have the capability to upskill your entire workforce NOW! CFCINDUSTRIALTRAINING.com 7042 Fairfield Business Drive Fairfield, Ohio 45014 +1 513.874.3225 info@cfcindustrialtraining.com MAY 2022

Case Study

Building Seaworthy Hydraulic Cylinders By Peter Claessens, Customer Support & Supply Chain Manager, Danfoss Power Solutions

loating liquefied natural gas vessels are used in offshore operations to produce and store liquefied natural gas before it’s transferred to tankers for transport to the mainland. To ensure the stability of these vessels, large hydraulic cylinders are often deployed in mooring tensioner systems. A floating liquefied natural gas (FLNG) compression and storage vessel for a high-profile offshore venture in West Africa needed 12 custom cylinders for its mooring tensioners. There were a number of requirements for the project: the cylinder supplier had to be capable of and highly experienced in producing extra-large custom hydraulic cylinders; it needed to have technically advanced, reliable solutions that would withstand the corrosive saltwater environment for decades of anticipated use; and it needed to be a collaborative partner to ensure project success. The company found its solution with long-time cylinder manufacturer Eaton Hydraulics, now part of Danfoss Power Solutions. At work in some of the world’s toughest applications across demanding sectors like oil and gas, civil engineering, and discrete manufacturing, Danfoss’ extra-large hydraulic cylinders are known for their quality, reliability, and advanced technology.

Project challenges Off the coast of West Africa, the FLNG vessel played a crucial role in a venture the company was supporting. Any issue with the ship’s stability could disrupt the entire project, creating not only safety concerns but also a considerable loss of time and money for all the stakeholders involved. With the stakes already high, the company’s requirements created some unique technical challenges. The mooring system, which compensates for the motion of the waves, called for extra-large cylinders in an atypical horizontal orientation, requiring a custom solution. Brutal offshore conditions complicated matters. Not only did the cylinders have to withstand continuous exposure to saltwater and sea spray, they also had to endure blowing sand from the Sahara desert in high wind conditions. With project operations expected to run for up to three decades, the solution had to perform well and be incredibly resilient. 8

MAY 2022

Mooring tensioners provide stability in brutal sea conditions.

Engineers from Danfoss collaborated closely with the company for several weeks to develop a custom system. This close working relationship enabled Danfoss engineers to gain a thorough understanding of the company’s requirements and design the best solution. Starting with the basics, 12 carbon steel hydraulic cylinders with built-in accumulators were specified for the FLNG vessel mooring system. Featuring a 600-millimeter diameter and 4,500-millimeter stroke length, the sizable cylinders have a design pressure of 230 bar (3,335 psi). Each is equipped with high-grade stainless steel piping and manifold blocks. The team next turned to solutions for corrosion protection, a critical consideration for cylinders used in offshore environments. Corrosion can impair cylinder performance and even lead to failure, resulting in unwanted downtime while raising safety and environmental concerns. Costs can skyrocket with even one day of downtime in offshore installations, emphasizing the importance of equipment reliability and ease of maintenance.

Corrosion protection Danfoss’ Eatonite anticorrosion laser cladding was specified as the cylinder rod coating. This proprietary, high-performance coating offers superior corrosion resistance in saltwater operations as well as optimized wear, scratch, and impact resistance. The material is very dense and allows no access to the base piston rod material, which is the usual cause of corrosion and coating failures. Originally developed for hydraulic riser tensioning systems on offshore platforms, Eatonite laser cladding was the first anticorrosion coating technology to earn DNV certification. The technology has been proven through more than 10 years of use in the field with no failures. WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

Laser cladding offers both short-term and long-term economic benefits. As a fieldrepairable coating, laser cladding significantly reduces maintenance costs and minimizes downtime. Typically, cylinders would need to be dismantled and sent to a repair facility for recoating, but laser cladding enables technicians to perform repairs in situ using common welding processes. Long term, the increased durability of properly designed equipment reduces operating expenses and total cost of ownership. Laser cladding produces a metallic coating with a strong metallurgical bond between the coating layer and substrate material. Using precise, state-of-the-art lasers as a controllable heat source, metallic powder is injected into the system by nozzles. Energy from the laser beam produces a shallow, molten cladding pool. Filler material powder is injected into the beam and the pool. As the laser beam passes through the area, the cladding pool solidifies rapidly, leaving the desired buildup of cladding material with minimal dilution of the base material. The cylinder rod is then turned and polished to the final surface parameters. The result is a protective coating with high ductility, resistance to bending, high strength, no cracks or pores, a smooth substrate adhesion, and uniform coating thickness. Depending on the cladding material, the rod coating can also be chemically inert, providing the highest level of corrosion protection. Cylinder piston rods require a surface that is highly resistant to wear and scratches due to the different conditions in which they operate. Eatonite laser cladding is hard at the outer surface but follows a smooth transition curve at the heat-affected zone. Other coatings may be either soft at the surface, indicating low wear resistance, or reach a plateau just below the surface, signifying possible issues with disbonding or delamination. Hydraulic cylinders in offshore applications are subject to impact damage from swinging chains and cables, falling and floating debris, or dropped equipment. These impacts can produce unwanted nicks, dents, and cracks, potentially leading to corrosion and leakage. To prevent this, properly applied and processed laser cladding can provide high impact resistance, allowing up to 30 Joules (22 foot-pounds) of energy without cracking. In nontechnical terms, when struck with a ball peen hammer, laser cladding may dent but will not crack. Furthermore, with a bond strength exceeding the strength of the steel-base metal, laser cladding will not spall or chip. Laser cladding has the necessary performance criteria to replace traditional coatings WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

used in offshore applications. However, care should be taken in its specification as not all coatings perform equally. Additionally, the selection of an experienced applicator and the definition of the proper performance criteria are as important as the coating material choice. Laser cladding can be supplied in combination with an integrated stroke measurement system. Where traditional stroke measurement systems are limited by length, Danfoss’ Hypos system can be used on infinite stroke lengths. The Applying Eatonite Hypos system also eliminates the need for deep hole drilling anticorrosion cladding. of the rod to encapsulate traditional measurement systems. The Hypos stroke measurement system enables operators to know the position of the piston in the cylinder at any moment. This capability allows early detection of leaks in the cylinder, making it possible to deal with issues promptly. Without such a system, the first sign of a problem would be performance loss or even sudden failure.

Delivery Having collaborated to design the best possible solution for the FLNG mooring tensioners, the teams next faced the challenge of building and delivering the 12 large cylinders with just a 10-month lead time. Manufacturing was carried out at Danfoss’ facility in Eindhoven, the Netherlands, home to a team of skilled assembly technicians and machining operators as well as a state-of-the-art test complex. Due to the combination of exceptional corrosion protection and an advanced sealing system, the Danfoss solution can withstand the application’s harsh environment, substantially extending the lifetime of the mooring tensioners and enhancing operational safety. At the same time, the solution lowers total cost of ownership by minimizing the risk of unplanned maintenance or equipment downtime.

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MAY 2022

COVER STORY

Winds of Change hydraulic turbines generate green energy By Michelle Berdusis, Wind Energy Business Development Specialist, and Mark Barnes, Senior Vice President, Global Business Development, Des-Case Corporation

ith an increasing drive toward renewable energy, wind power is now globally accepted as a leading technology to deliver “green” energy. Well established in Europe for the past 30 years, other countries worldwide are embracing wind energy as a clean, reliable source of power. China has committed to generating 50% of domestic power from wind energy. At the same time, Denmark is close to being self-sufficient in wind power generated offshore in the North Sea. However, as more countries become reliant on wind power, there’s been an increased focus on turbine asset reliability to ensure peak power production at low overall operating costs. Conceptually, wind turbines are simple in design, consisting of a rotor that converts rotational energy into electrical energy through a generator. Rotational motion transfers to the generator through the drive train, which often, though not always, consists of a gearbox to increase shaft speeds of the rotor to drive the generator. Because wind turbine gearboxes are critical, significant research, engineering, and design have gone into their reliability with good effect. In addition, turbine owners, operators, and OEMs developed several maintenance strategies focused on increasing gearbox reliability. These practices include gearbox design, metallurgical improvements, specialized lubricant formulations, optimized fluid filtration, and cooling. However, the same focus has not been spent on wind turbine hydraulics. Not every turbine uses hydraulics, though it is estimated that approximately 50% of them have some form of hydraulic system, a trend that is likely to grow as the size of rotors increases, requiring greater torque (force) to change the angle (pitch) of the blades.

Hydraulics in wind turbines Hydraulics performs several roles in wind turbine operations. The most common is brake and pitch control. Pitch refers to the angle of the blade. To maximize power production efficiency, blade pitch angles are constantly adjusted through a proportional valve-controlled system. The brake refers to a braking mechanism used to slow and lock the rotor from turning under adverse conditions, for example during high wind speeds. This is a safety mechanism that is required to prevent overspeed of the turbine, which could result in structural failure and damage. Some turbine designs use hydraulic rotor and yaw systems to control the movement of the nacelle to yaw (rotate) in and out of the wind. This is to optimize production and prevent damage or failures during extreme conditions. While wind turbine gearbox repairs and replacements can cost up to $500,000, hydraulic failures cost far less, ranging from $20,000 to $30,000 to replace failed pitch cylinders. However, as we become more reliant on wind power to provide base power loads, avoiding downtime through optimum maintenance of the gearbox and hydraulic system becomes a strong focus, particularly for self-performing owner-operators responsible for maintenance and operational costs. Many wind farms operate under

MAY 2022

power-purchase agreements that contain severe fines and penalties for unscheduled power interruptions. The complexity of performing maintenance 80-120 meters (270-400 feet) in the air means that any “up-tower” maintenance task comes with additional challenges. The work requires specialized training and safety procedures, a necessity exacerbated by the growth of offshore turbines with drastically greater safety hazards.

Fluid cleanliness Like any industrial hydraulic system, the main components of a wind turbine hydraulic system are pitch cylinders (actuators), accumulators, seals, a hydraulic reservoir and supply lines, pumps, hydraulic valves, and the control panel. Like any hydraulic system, the reliability of one in a wind turbine is tied to the health and cleanliness of the hydraulic fluids. While design certainly plays a role, an estimated 50% to 70% of hydraulic system issues in wind turbine applications relate directly or indirectly to fluid health and cleanliness. With contamination, common causes include solid particles ingested from the outside or internally generated due to wear, moisture from humidity in certain regions, and degraded fluid from poor lubricant management. Perhaps the most damaging is solid particle contamination. When a particle trapped between two surfaces removes material from one of those surfaces, the result is what’s known as three-body abrasion (see figure 1). As much as 66% of lubrication-related wear is attributed to three-body abrasion. Hydraulics are particularly prone to it because of the tight clearances found in high-pressure components. Even if outright failure does not occur, particles trapped between the moving surfaces of a valve can result in an effect known as stick-slip, in which the valve momentarily locks while the particle is lodged between the surfaces. Stick-slip can result in suboptimal pitch controls. Another common problem with wind turbine hydraulics is seal failure and resulting fluid leakage. For an industry that prides itself on delivering

FIGURE 1: Three-body abrasion causes cutting wear in sliding contacts.

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

“clean” energy, this is not only a direct cost but an environmental concern. While hydraulic seal failure can occur from several factors, it is estimated that 22% of failures are due to contamination from abrasive wear.

Moisture contamination While some wind farms are located in desert environments, many onshore ones are found close to a coast due to the favorable wind conditions. Similarly, a significant and increasing number of wind farms are located offshore. These environments make for challenging operating conditions. The combination of high humidity, elevated operating temperatures inside the nacelle, and the fluctuating ambient conditions due to temperature shifts leads to high moisture content, which can cause rusting and hydraulic pump cavitation, as well as contribute to fluid degradation and varnish formation. The easiest way to protect a wind turbine hydraulic system from moisture contamination is with a desiccant breather to dry and clean the air that enters during normal operations and to create a dry headspace environment inside the reservoir (see figure 2). Just like placing a sachet of desiccant inside a sealed box of consumer electronics, desiccant breathers are effective at preventing damage to the hydraulic fluid by actively drying the headspace and enhance the oil due to the effect of Henry’s law. Desiccants are effective in eliminating moisture from wind turbine hydraulics. They also play a role in controlling particle contamination by preventing particle ingress from the outside during volumetric exchange

FIGURE 2: Desiccant breather in a wind hydraulic power unit.

or thermal syphoning. High-quality desiccant breathers contain filter elements that offer 99% efficiency at preventing particles down to 1 micron from entering the system. However, desiccant breathers alone will not help achieve fluid cleanliness below the recommended ISO 16/14/11 target. To attain optimum fluid cleanliness, turbine operators must carefully select and maintain full-flow hydraulic filters. Filters with a beta efficiency in excess of 1,000 at 3 microns are recommended. Filters should be properly installed, properly maintained, and replaced

before they plug and go into bypass. Even with desiccant breathers and high-efficiency full-flow filters, harsh operating conditions keep wind turbine hydraulic systems from achieving optimal particle and moisture targets. Because of this, wind turbine operators should take routine oil samples every 3-6 months to measure contamination levels along with fluid and component health. These inspections should include particle counting using the ISO 4406 standard and an accurate water test using the ASTM D6304 Karl Fischer moisture method.

Offline filtration Operators who cannot meet the required cleanliness and dryness targets should consider supplemental offline filtration. Installed in kidney loop fashion – drawing off the reservoir and returning the cleaned fluid back to the oil sump – offline filtration is an economic way to improve particle and water levels (see figure 3). These systems are equipped with a radial depth media element with a beta efficiency in excess of 2,000 at 2 microns and a superabsorbent polymer to remove free and emulsified water. They can quickly reduce contamination to optimum levels.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Aside from particle and moisture problems, varnish is a common but often overlooked contaminant. Varnish is a sticky resinous material caused by the degradation of the hydraulic fluid through a combination of thermal and oxidative stress. While the term varnish applies to many tribological mechanisms, its result is deposits inside the reservoir,

FIGURE 3: Offline filtration in a wind turbine hydraulic system.

cylinders, accumulators, and cooler. Left unchecked, varnish can plug the filter and further exacerbate valve stiction issues by serving as “flypaper,” helping particles stick and remain trapped inside the valve. Wind turbine hydraulic systems are a prime breeding ground for varnish due to changes in ambient temperature and high humidity. Fortunately, radial depth filtration can control varnish, as it does for particles. Oil flows through hundreds of layers of cellulose media, trapping varnish and its precursors in the filter, and halting the cycle of varnish formation and deposition. Removing insoluble varnish from the oil increases the hydraulic fluid’s solvency, dissolving some of the “back-on” deposit into the oil to be extracted through offline filtration. An operator who suspects a varnish problem – often identified by darkening of the oil – should take an oil sample and conduct a membrane patch colorimetry test. The MPC test provides a ranking on a scale of 0-100 to indicate the likelihood that varnish will form (see figure 4). An operator who finds a high MPC should deploy a varnish removal system in conjunction with a solvency agent to solubilize the varnish. Wind turbines are challenging applications. The combination of remote locations, environmental conditions, and long timeframes between maintenance cycles mean that achieving optimum reliability cannot be taken for granted. While FIGURE 4: A membrane patch colorimetry test for gearbox cleanlivarnish potential. ness has long been a focus, hydraulic systems are rightly garnering more attention. With over 50% of all hydraulic system issues tied to contamination, focusing on its control with desiccant breathers and offline filtration is a necessity for wind power to deliver clean and reliable energy long into the future.

•

MAY 2022

The Odd Couple A COMPONENT THAT FLOATS YOUR BOAT By Brad Longmuir, Regional Sales Manager, Holmbury Inc.

A vertical hydraulic boat lift.

• They are fast. Before hydraulic boat lifts, you had to lift boats either by hand, with a boat-lift wheel, or by attaching a motor to a boat-lift winch. While a motor made it more convenient, it also made it more complex, adding noise and reducing speed. Hydraulic lifts are simpler, faster, and quieter. There are multiple styles of boat lifts, but cantilever and vertical are the two that use hydraulics. Of the two, cantilever hydraulic boat lifts are the simplest and typically require less maintenance. The weight of the boat is transferred from a swing carriage to the fixed-base frame. The carriage is designed to swing forward during lifting and back while the frame is down. The swing carriage is connected to a hydraulic ram that is powered by an electric motor and pump to do the work of lifting and lowering. Cantilever lifts are the most common and work best in shallow water of 3-6 feet with minor water fluctuations and a firm lake bottom. Cantilever boat lifts are typically used with cruisers, speed boats, and boats for water sports. Vertical boat lifts are widely recognized as one of the best lifting designs available. They tend to support bigger boats than cantilever lifts do. The cable design allows for all of the hydraulic components to be above the water line, unlike the cantilever lifts that have the hydraulics and fluid lines below the water. Hydraulic components above water are more reliable and require less maintenance. Hydraulic vertical boat lifts work in soft, semi-firm, and firm lake bottoms and typically in 3-7 feet of water with minor water fluctuations. The hydraulic box that powers the lifts typically uses quick disconnects. It is sometimes necessary to disconnect the hydraulic box from the lift, for example, for winter storage, dock renovation, or potential flooding. The quick disconnect allows for easy and safe disconnection of the hydraulic hoses. Holmbury quick disconnects work by hand, without tools, making them perfect for boat lifts. Because of mechanical advantage of the threaded connection, you can connect hoses with residual pressure in the lines from thermal expansion. Why would someone need a boat lift? Leaving a boat in the water all year causes damage and decreases its value, whether it’s made of fiberglass, aluminum, or plastic. A boat lift helps prevent scum and slime buildup. A boat that is consistently affixed to a dock or buoy is vulnerable to damage from rain, high winds, and changing water levels. A boat lift helps keep a boat in good condition. Hydraulic boat lifts help keep boats safe and secure, and Holmbury quick couplers help make their maintenance quick and easy.

hen the COVID pandemic hit the U.S. in March 2020, lots of things changed. People worked from home, businesses shut down, and many activities came to a screeching halt. One industry that seemed to boom was the marine industry, as families had more time to spend on the water. Hydraulic boat hoists became a near necessity for people who suddenly had the time and money to spend on leisure activities. Holmbury quick disconnects became a go-to component for manufacturers of hydraulic boat lifts, and this article shows why these couplers are ideal for this specialized product. Prior to the mid-1970s, boats were lifted with crane-like structures called davits, which were challenging for one person to operate. A major breakthrough came in the 1980s when aluminum replaced galvanized steel as a structural material. Though more expensive than steel, its longevity and corrosion resistance made it a superior alternative. Today boat lifts made of aluminum are considered superior to those of 30 years ago. The methods to lift the boat with a cradle system have also improved, with hydraulic cylinders commonplace. Hydraulic technology has made the act of raising and lowering a boat incredibly efficient and faster than a manually operated boat lift. Hydraulic boat A hydraulic boat lift power box. lifts have several benefits over manual ones with cables and pulleys. • They are simple. A hydraulic boat lift doesn’t involve cables or pulleys, making it easy to own and operate. It generally requires minimal maintenance, especially when created with a welded construction versus a bolted stand. These designs can accommodate nearly any boat and often come with remote-control operation for convenience. • They are quiet. Manual boat lifts make rattling noises during operation. With a hydraulic boat lift, operation is nearly silent.

MAY 2022

•

A cantilever hydraulic boat lift. WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

N F PA U P D AT E

Rise in February Hydraulic Shipments The latest data published by the National Fluid Power Association shows continued growth in the 12-month moving average of pneumatic, hydraulic, and total fluid power shipments. The year-to-date change for total fluid power shipments in February 2022 is 18.8%. Raw index data show that pneumatic shipments stayed relatively the same when compared to last month, while mobile hydraulic and industrial hydraulic shipments are up. The following charts are drawn from NFPA’s Confidential Shipment Statistics (CSS) program.

Hydraulic and Pneumatic Shipments

SHIPMENTS

Raw Index Data, Index: 2018=100

MONTH

TOTAL FLUID POWER

TOTAL HYD.

TOTAL PNEU.

Dec. 2021

20.1

20.9

16.3

Jan. 2021

17.5

20.8

7.6

Feb. 2022*

18.8

21.3

7.4

*Preliminary data subject to revision.

Shipments – Cumulative year‐to‐ date % change (2021 vs. 2020)

This graph of raw index data is generated by the total dollar volume reported to NFPA by CSS participants and compared to the average monthly dollar volume in 2018. For example, the February 2022 total dollar volume for pneumatic shipments is 103.5% of the average monthly dollar volume in 2018. (Base Year 2018 = 100)

The table above is expressed in terms of cumulative percent changes. These changes refer to the percent difference between the relevant cumulative total for 2022 and the total for the same months in 2021. For example, February 2022 pneumatic shipments figure of 7.4 means that for the calendar year through February 2022, pneumatic shipments increased 7.4% compared to the same time-period in 2021.

Pneumatic, Mobile and Industrial Hydraulic Orders 12/12 Ratio Each point on this graph represents the most recent 12 months of orders compared to the previous 12 months of orders. Each point can be read as a percentage. For example, 143.7 (the February 2022 level of the industrial hydraulic series) indicates that industrial hydraulic orders received from March 2021 to February 2022 were 143.7% of the orders received from March 2020 to February 2021. (Base Year 2018 = 100)

Total ‐ Hydraulic and Pneumatic Shipments 12 Month Moving Average This graph of 12-month moving averages shows that in February 2022, the moving average for shipments increased across the board. (Base Year 2018 = 100)

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

MAY 2022

I F P S U P D AT E

Executive Profile

CELEBRATING 60 YEARS

Q. W hy did you pursue certification, and how has it helped your career? A. The fluid power distributor I worked for required a CFPHS certification

to work in an outside sales position. So I immediately began researching the certification requirements. I was the first female at the company to take the test, and I personally felt a great deal of pressure to pass. Fortunately, I was able to study for several months and pass on the first try! The CFPHS certification proved to be a launching point for me, allowing me to advance in my career and become the company’s first female outside salesperson. Ten years later, I left and formed OneHydraulics, and my love of the industry has only grown since. As a young female in a predominantly male industry, I know that my certification has given me a great deal of credibility.

Q. W hat have you learned by working in this industry?

A. One of the most fascinating things I’ve learned is just how many industries depend on fluid power. From agriculture to oil and gas, space to wind energy, mining to amusement parks, there is almost no industry untouched by fluid power. And that means the applications are always changing, and there’s always something new to learn.

Chauntelle Baughman, CFPHS, President and Cofounder, OneHydraulics

Q. W here do you see the industry heading in the next 10 years?

A. I expect to see substantial improvements in efficiencies as fluid power systems are married to ever more sophisticated controls.

Q. H ow did you get started in the fluid Q. W hat advice would you give someone starting out in power industry? A. I graduated from Texas A&M University with

a degree in industrial distribution with job offers from many distribution companies in a variety of fields including plumbing, building materials, and fluid power. On the advice of my father, I accepted a position at a fluid power distribution company in Houston because I felt that the industry would be the most personally challenging. As it turns out, I fell in love with the industry and I’ve never left.

the industry? A. Never confuse intelligence with experience. I tell this to my new employees all the

time. It can be overwhelming to learn about everything from reading hose dash sizes to calculating pump displacements and reading schematic symbols. There are many wonderful people in our industry who have mentored me throughout my career, patiently teaching me all the nuances. These people have decades of experience and have seen hundreds of applications, encountered thousands of problems, and hopefully just as many solutions. The IFPS certifications will certainly help set a benchmark of your fluid power intelligence, but the experience will really come over time. You just need to be patient, curious, and never afraid to ask questions.

Q. How and why did you get involved Q. W hat are some of your hobbies and interests? in IFPS, and what have you gained professionally and personally? A. I’ve known about IFPS since I began my career

in fluid power. But only in the past few years have I had the opportunity to step in and become more involved. I’ve been able to meet new people and collaborate with others. Being a part of IFPS has shown me not only the challenges facing our industry, but also how to view those challenges with perspectives besides my own. 14

MAY 2022

A. My hobbies and interests are comically diverse. I always set goals for myself at the beginning of each year, trying to learn one new skill or industry I’ve never learned before. One year I decided to write novels and learn the publishing industry, and another I picked up baking and food canning. But overall, my favorite hobbies are reading, writing, copywriting, and spending time with my husband and two awesome kids.

Q. W hat is something people would be surprised to learn about you? A. I have written two novels and been on the Amazon bestsellers list.

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

I F P S U P D AT E

Newly Certified Professionals February 2022 MASTER MECHANIC

holds IHM, MHM and PM certifications Joshua Grisolia, The Boeing Company SPECIALIST

holds HS and PS certifications Todd Taylor, Flint Hydraulics

efficient reliable tight

PNEUMATIC SPECIALIST

Todd Taylor, Flint Hydraulics ELECTRONIC CONTROLS SPECIALIST

Quinn Anglada Alik List Scott Sardina, PE, Waterclock Engineering Chase Zacharias

Plugs with integrated molded NBR or FKM seal. Automatically assembled with integrated control. Our products can be found worldwide in hydraulic applications and drive technology. We stock for you.

HN 8-WD | SCREW PLUG

Our solution

HYDRAULIC SPECIALIST

Brian Devine, Devine Hydraulics Aaron Dubina, Devine Hydraulics Edward Gauthier, Devine Hydraulics Yandiel Cepero, Electro Hydraulic Machinery Co. MOBILE HYDRAULIC MECHANIC

Joseph Barbieri, Altec Industries Joseph Lynch, Altec Industries Cody Miller, Altec Industries Thomas Riney, Altec Industries Dennis Hardee, DK Hardee Heavy Duty Nick Ziegler, Ottertail Power Jacob Berks, SMUD Joshua Grisolia, The Boeing Company

Mobile - Portable

HII

HYD-4404

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

mail@heinrichs-usa.com | +1 859 371-4999

heinrichs-usa.com

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

CONNECTOR & CONNECTOR

It’s our turn.

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

Mark Lewis Michael Anderson, Alfred State College Augustus Kirby, AM/NS Calvert Chengwu Deng, Disneyland Resort Christopher Binsley, Motion Industries Keenan Fraylick, Parker Hannifin Daniel Hogan, Parker Hannifin Alexander Kraski, Parker Hannifin John Lee, Parker Hannifin Sean Weber, Parker Hannifin Nate Borries, Parker Hannifin

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

Made in the USA

MAY 2022

I F P S U P D AT E

CELEBRATING 60 YEARS

Upcoming Events Webinar: Understand the Application of Valves Tom Blansett, CFPAI, IFPS technical director, and Donna Pollander, ACA, IFPS executive director, present an interactive training session, Understand the Application of Valves, March 12 at 12 noon Eastern time. Who should attend? Anyone planning or preparing to take the Hydraulic Specialist certification test, and individuals who want to learn more about the application of valves. You'll also see how our interactive training modules work and have the opportunity to win prizes too!

THE CORE OF GREEN ENERGY

Webinar: Selection of Hose Size for Laminar Flow BJ Wagner, CFPAI/AJPP/AJPPCC, CFPHS, CFPMMH, presents a webinar titled Selection of Hose Size for Laminar Flow, June 23 at 12 noon Eastern time. He’ll look at the differences between laminar and turbulent flow as well as the benefits of laminar flow conditions. He’ll also review calculations to size a hose and how to use a nomograph chart. Register at www.ifps.org/web-seminars.

Mark Your Calendar Instructor Workshop 3 Accredited Aug. 23-25, Denver, Colorado. Annual Meeting and 3 2022 Hall of Fame Induction Sept. 26-29, San Diego. Annual Meeting and 3 2023 Hall of Fame Induction LMP low and medium pressure filters used in lubrication circuits available in standard and extended duty configurations.

Dual & Single stage filter elements

FHB

High pressure manifold mounted filters to optimize circuit design, reduce Fit-Form-Function package size, and elements produced with High performance potential leakage. Flow rate to 128 GPM and media providing 4640 PSI. excellent dirt holding capacity for extended life in lube systems.

LMC

SGEA

SAW 115

The bell housings are used as connection between IEC electrical motors, size 80 to 355, and pumps with ISO and SAE flange.

The flexible couplings are used for the connection of IEC electric motors size 63 to 400 and hydraulic pumps. Made in aluminum, cast iron or steel, they can be processed according to ISO, SAE and DIN.

Protection from moisture and particulate contamination in lubricant and equipment. Max air flow up to 453 l/min.

PASSION TO PERFORM

www.mpfiltriusa.com (215) 529-1300 sales@mpfiltriusa.com

MAY 2022

mpfiltri.com

Sept. 25-28, 2023, Milwaukee. LMP

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

I F P S U P D AT E

IFPS Spring Meeting Highlights

Back row from left: Brian Wheeler, Scott Sardina, Mo Shahin, Jim O’Halek, Brian Kenoyer, Garrett Hoisington Denis Poirier, Rocky Phoenix, and Steve Blazer. Front row from left: Chauntelle Baughman, Donna Pollander, and Lisa DeBenedetto.

CELEBRATING 60 YEARS

The IFPS spring meeting, held in Charleston, South Carolina, was conducted in person and virtually, and it’s exciting to report that meeting attendance was 90% in person! IFPS couldn’t operate without the passion, expertise, time, and effort of the dedicated volunteers who make up our board of directors. They have a lot planned for 2022 and are looking for support from the fluid power community. If you have interest or expertise in any of the following areas, please contact Donna Pollander, IFPS Executive Director, by emailing dpollander@ifps.org. Committees meet via conference calls several times a year. • The Certification Committee is looking for volunteers to help develop a hydraulic technician certification that will cover both mobile and industrial applications. • The Education Committee is looking for volunteers to help increase IFPS educational online and in-person content. • The Membership Committee has launched a mentorship program. Its goal is to connect early-career individuals and experienced fluid power professionals. The committee will look for mentors and mentees in the upcoming months. Details forthcoming. • The Marketing Committee is looking for creative-minded volunteers to help with social and digital marketing. Besides the work accomplished during the meeting, the attendees had some fun too. They enjoyed a carriage ride through historic Charleston, a Fort Sumter tour, and pneumatic bottle races.

IFPS invites all members to join in the comradery and networking at our next meeting, Sept. 26-29, in San Diego. So mark your calendar!

Brian Kenoyer, Steve Miller, Mike Hanley, Mo Shahin, and Bradley Wagner.

O-Ring Port Weld Fittings • O-Ring Boss • SAE 4-Bolt Jon Jensen builds a pneumatic bottle racer.

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

MADE IN USA

Bob Sheaf uses pneumatics to inflate the motor for the bottle racer. WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

(509) 533-0479 • Fax (509) 534-2998 fluiddesignproducts.com email: sales@fluiddesignproducts.com

1-800-774-7554 MAY 2022

I F P S U P D AT E

AVAILABLE IFPS CERTIFICATIONS CFPAI Certified Fluid Power Accredited Instructor

Tentative Certification Review Training

CFPAJPP Certified Fluid Power Authorized Job Performance Proctor

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.

CFPAJPPCC Certified Fluid Power Authorized Job Performance Proctor Connector & Conductor

HYDRAULIC SPECIALIST Aug. 29-Sept. 1, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written test Sept. 1.

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)

PNEUMATIC SPECIALIST June 13-16, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written test June 16. ELECTRONIC CONTROLS SPECIALIST Aug. 8-11, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written test: August 11, 2022 CONNECTOR & CONDUCTOR Nov. 15-16, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written test Nov. 17. MOBILE HYDRAULIC MECHANIC Oct. 10-12, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written and JP test Oct. 13. Online review for written test. Contact info@cfcindustrialtraining.com. IFPS members can email askus@IFPS.org for a 20% off coupon code. Test fees not included. INDUSTRIAL HYDRAULIC MECHANIC July 18-20, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written and JP test July 21. INDUSTRIAL HYDRAULIC TECHNICIAN Onsite review training for small groups. Contact IFPS for details. MOBILE HYDRAULIC TECHNICIAN For dates, call 513-874-3225 or contact info@cfcindustrialtraining.com. PNEUMATIC TECHNICIAN and PNEUMATIC MECHANIC For dates, call 513-874-3225 or contact info@cfcindustrialtraining.com. JOB PERFORMANCE TRAINING Online review. Contact info@cfcindustrialtraining.com. Reviews includes stations 1-6 of the IFPS mechanic and technician job performance tests. Members can email askus@IFPS.org for a 20% coupon code. Test fees not included. To register, contact info@cfcindustrialtraining.com. LIVE DISTANCE LEARNING JOB PERFORMANCE STATION REVIEW Contact info@cfcindustrialtraining.com for information.

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

MAY 2022

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

I F P S U P D AT E

Written Certification Test 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: June 2022 Tuesday 6/7 • Thursday 6/23 July 2022 Tuesday 7/12 • Thursday 7/28 August 2022 Monday 8/8 • Thursday 8/25 September 2022 Tuesday 9/13 • Thursday 9/29

JOB PERFORMANCE TEST LOCATIONS Arizona Nova Scotia Pennsylvania California Texas Colorado Washington Florida Georgia Wyoming Maine Western Michigan Australia Minnesota Montana New Jersey

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

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

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

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

CELEBRATING 60 YEARS

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

MAY 2022

TEST YOUR SKILLS

Intercooler

he generic term “supply side” is often used to refer to the complete package that includes the compressor, drive motor, and associated hardware, as well as the filters and coolers used to remove the contaminants and water resulting from the compression process. Also included will be items such as the receiver and capacity control devices. In addition to selecting the size and type of compressor to be used, the following items need to be considered in the flow path as the air is transported from free air at the compressor inlet to the receiver prior to being dispersed to the points of use. Location of the compressor. The foundation on which the compressor is mounted should be substantial enough to provide support and absorb vibration from the compressor. The base should permit the compressor to be mounted level and not subject to any deflection in the drive. The compressor room should also have the means to dissipate the heat generated by the compressors. Compressor inlet location. The inlet temperature of the compressor can affect the delivery by almost 20%. Based on a normal intake temperature of 60°F, the compressor delivery will increase to 118% for an inlet temperature of -20°F and be reduced to 83.8% at an inlet air temperature of 160°F. Ideally the compressor inlet should be mounted outdoors at least six feet above the ground. It should be screened and protected from direct ingestion of rain, snow, and blowing dust or debris, as well as exposure to vermin. The intake should not be mounted directly adjacent to a wall or in a confined area to minimize vibrations caused by the intake pulsations. The intake piping should be adequately sized for the airflow and have minimal bends; any bends should be comprised of large radius elbows. The inlet filter should be mounted as close to the compressor as possible. The inlet filter protects the compressor from particles larger than 20 to 80 microns that may cause wear to rings and other close fitting parts. Compressor discharge filtration. The compressor inlet filter is sized to eliminate contaminants that could damage the compressor. During compression the remaining particles have been concentrated as a function of the compression ratio. The compressor also introduces wear particles into the air stream and residual lubricating oil. Compressors that utilize oil as a cooling and sealing media will have a sump and separator to recover the compressor oil. Additional filtration will further remove contaminants, including particulates and residual compressor oils, after the air is cooled and the water removed. Cooling. During compression, air molecules become compressed and generate heat, which in turn reduces the volumetric efficiency of the compressor. Losses are kept to a minimum by dissipating the heat through fins on the compressor for air-cooled compressors or into the coolant for liquid-cooled compressors. The compressed gas also cools in the receiver. In a typical two-stage reciprocating piston compressor, a large first-stage piston feeds compressed air into a smaller second-stage piston. To improve volumetric efficiency, an intercooler cools the compressed air between stages. The intercooler often consists of a finned tube cooled by the flywheel fan. The heat of compression is transferred from the hot air to the core tube, to the fins, and then to atmosphere. Cooling is aided by the flywheel fan, which also cools the case, cylinder, and head of the compressor. 20

MAY 2022

Compressor isolation. If a shutoff valve First-stage Second-stage cylinder cylinder is installed in the discharge line to permit Two-stage compressor with intercooler. maintenance of the compressor without bleeding down the entire air system, an overpressure safety valve constructed to ASME standards must be installed upstream of the shutoff valve. A bleed-off valve should be installed to permit any residual pressure to be released prior to beginning maintenance. Follow proper lock-out tag-out procedures to ensure the compressor is not able to start inadvertently due to the normal air demand control sequence. Water removal. Water vapor, which is held naturally in air, is compressed with the air and will precipitate out during the compression process. If unconditioned compressed air is sent downstream it will contaminate the piping system along the way with liquid water that drops out of suspension and enters air tools and machinery. For this reason the water must be removed. An aftercooler attached to the compressor outlet will remove most of the water before it gets into the piping system. In practice, aftercoolers placed immediately downstream of a compressor can remove approximately 85% of the moisture that passes through the compressor. For example, 1,000 cu-ft. of saturated air at 14.7 psia and 80°F contains about 1.58 lb. of water. Compressing that air to 100 psig and then cooling it back to 80°F will reduce the moisture content by about 90% to about 0.2 lb. The receiver conditions air the same way. As air cools in the receiver, water condenses and falls to the bottom of the receiver, where it is drained off. Other methods used to further reduce the water content in compressed air include refrigeration or desiccants such as activated alumina. Sumps that collect the condensate must be designed so the drained fluid can be captured for proper disposal.

Compressor types Air compressors commonly used for power and control functions are reciprocating piston, vane, rotary screw, lobe, scroll, and centrifugal types. A vacuum pump is treated as a compressor that works at less than atmospheric conditions. Within each of these types of compressors, additional distinction can be drawn for single-stage, dual-stage, or multiple-stage, and oil-injected or oil-less. In single-stage compressors the air passes through a single compression stage. The effective maximum compression ratio is 11:1 limiting effective outlet pressures to 1,030 kPa (150 psig.) In dual- or multi-stage compressors the air is passed into an additional compressor that further elevates the pressure. The air passes through an intercooler to reject some of the heat of compression to improve compressor efficiency. When discharge pressures of 1,750-2,400 kPa (250-350 psig) are required, two- or three-stage compressors are preferred. For extremely high pressures above 4 MPa (600 psig), four- or five-stage compressors will be used. Reciprocating piston. The reciprocating piston compressor is similar in design to an internal combustion engine with a piston connected to the crankshaft by some form of connecting rod. The compressor can WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

have multiple pistons and may be either single acting or double acting, resulting in compression strokes in both directions of the piston. Multistage compressors will connect the discharge from one cylinder though an intercooler to another cylinder of a smaller size to increase the compression ratio. Lubrication of the crank mechanism and pistons varies based on the design. For applications where trace amounts of oil are tolerated, the lubrication is similar to conventional internal combustion engines, using positive lubrication or the splash type commonly found on small engines. For oil-less or oil-free compressors the bearings will be prelubricated and sealed, the piston seals will be made of a low friction material that is self-lubricating and heat resistant. Valves identified as reed, disc, or strip are check valves that open with a very low differential pressure. Larger compressors may use an automotive style valve system driven off the crankshaft. Air cooling is the most common method, with liquid cooling limited to large compressors or those with high duty cycles. Rotary screw. According to the Compressed Air and Gas Institute, the oil-injected rotary screw compressor has become the dominant type of compressor for a wide variety of industrial and mining applications. The rotary screw compressor is a positive displacement device that utilizes two intermeshing helical rotors in a stator housing. The main rotor consists of a series of helical lobes that mesh precisely with the corresponding grooves in the secondary rotor. As the rotors turn, air that enters the inlet is transported progressively along the Rotary screw compressor. rotors away from the inlet to the discharge port. Oil is injected into the compression chamber to provide sealing, lubrication, and cooling. The oil used is typically a synthetic lubricant to provide long life at high compressor operating temperatures. The air-oil mixture leaving the compressor is then passed into a sump/separator to recover the oil, which is then filtered, cooled, and reinjected into the compression chamber. Oil-free rotary screw compressors utilize external gears to prevent the intermeshing rotors from making physical contact. The lack of oil for the sealing and cooling requires higher rotor speeds, and single-stage versions produce less air volume since none of the heat of compression is removed from the air during the process. Vane. Sliding vane devices can be designed to operate as an air compressor or vacuum pump. Sliding vane compressors consist of a cylindrical stator with a smaller diameter rotor mounted eccentrically inside. The stator chamber is the same width as the rotor. The diameter difference of the rotor and stator and the thickness of the chamber will determine the amount of air produced with each revolution of the rotor. The rotor has a number of slots fitted with vanes that are free to slide in and out. Driving the rotor causes the vanes to extend due to centrifugal force. The vanes form a seal against the inside diameter of the stator, the rotor, and the Vane compressor. ends of the cylindrical stator. The inlet port allows air to be drawn in on the increasing volume side of the eccentric, where the vanes slide out of the WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

rotor. As the chamber formed by two vanes, the rotor and the inside edge of the stator reaches the major diameter, the inlet port is blocked, and the discharge port is then opened as the chamber now passes to the decreasing volume area caused by the eccentric. The vanes are forced back into the rotor and the air is forced into the discharge port by the reduced volume. Oil is typically injected into the air stream to provide lubrication, cooling, and sealing of Lobe compressor. the moving parts. Lobe. The twin lobe compressor uses gears to synchronize two intermeshing lobe-shaped rotors. The air is transported around the outside of the housing from the inlet to the outlet. The meshing of the rotor lobes forces the air out on the discharge side, while the separating of the lobes on the inlet side draws air into the pumping chamber. These compressors are typically used for large volumes of low-pressure air, or in transporting process gasses for scrubbers and similar applications. Scroll. The scroll compressor utilizes an Scroll compressor. oscillating spiral that fits inside a mating fixed spiral or scroll. The orbiting movement of the oscillating spiral creates a flow path that progressively moves from the inlet to the outlet. The precise shape and fit of the two scrolls provides a tight seal without actual metal-to-metal contact and does not require lubrication. The result is a continuous discharge of oil-free air with no pulsations and very low noise. Currently they are limited to 3.75 kW (5 hp). Centrifugal. Centrifugal compressors are usually used in large horsepower applications, typically above 300 hp. The centrifugal compressor is a nonpositive displacement compressor technically defined as a dynamic compressor. The air is accelerated and compressed as a result of impacting the rotating vanes or impellers. Stationary guide vanes are used to direct the airflow within the compressor. Multistage compressors may be inline on a single shaft with intercoolers located between the stages, or integrally geared consisting of a set of separate impellers and housings connected by a common drive gear. Performance of the centrifugal compressor is significantly affected by the discharge pressure and the rotaCentrifugal compressor. tional speed of the compressor.

•

TEST YOUR SKILLS

1. 2.

Which of the following is the preferred location for the compressor inlet? a.Inside the compressor room. b.Inside the building close to the main demand location. c.Outdoors at least 6 ft. (2 m) off the ground. d.Outdoors close to a wall and an adjacent corner. e.Indoors under a stairwell. Which compressor type is defined as a dynamic compressor? a.Centrifugal. b.Reciprocating piston. c. Rotary screw. d. Vane. e. Lobe.

See page 31 for solutions. MAY 2022

SPECIAL AD SECTION

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Efficient Slip-In Check Valves Support Axial and 90 Degree Flow Paths

Marine Duty Electric Clutches Ogura electromagnetic clutches provide a quick and easy engagement of a hydraulic pump, winch drives or other marine components. Available torque range is 100 pound feet to 1500 pound feet with single-face friction designs. Multiple disk units can generate torques over 8,000 pound feet. Large bearings, e-coating and a single piece bi-directional spring provide durability in harsh environments. Watch our video on how they work: https://ogura-clutch.com/video-mobile.php

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MAY 2022

Inserta® IGS (steel) Check Valves, Guided Disc, Slip-In Type, have favorable pressure drop profiles, and may be considered in both axial and ninety degree flow path applications. Ninety degree flow path cavity examples are documented in the product literature, and may be found on the company website. No specialized cavity form tooling is required. They may be retained using Inserta® IGSP Retaining Assemblies. The photo shows a cutaway of the guided disc configuration versus a standard disc type valve. The patented guided disc design affords improved longevity in applications prone to turbulence, in higher cycling and higher flow applications, and is preferred for ninety degree flow paths. These valves may be considered as potentially more efficient alternatives to typical thread-in cartridge valves.

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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

Hydraulic Noise and Shock Suppressor

Cordis Electronic Proportional Pressure Controls Suppressor

Accumulators

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

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

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

Known for reliability, innovation and focus on miniature pneumatics, Clippard’s new revolutionary micro-controllers utilize the proven EVP and DVP lines of Clippard proportional valves allowing for steady, repeatable downstream pressure as demand or processes change. The result, a precise, linear digital pressure control within a closed-loop system with ultra high resolution (≤5 mV) and repeatability. Made in the USA.

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Don’t Compromise – that hydraulic flange you want maybe at MAIN MAIN stocks 10,000+ hydraulic flanges and manufactures components in 4-7 days in the USA. SAE J518 Code 61 and J518 Code 62, JIS, DIN, ISO 6162, ISO 6164, and specials with socket-weld, buttweld, ORB, BSPP, etc.; all geometries, flange heads, flange adapters; in carbon, stainless, cupro-nickel, ductile, aluminum, etc. Sixty years’ experience plus SAE and ISO technical committee experience. MAIN Manufacturing Products, Inc. 800.521.7918 https://mainmanufacturing.com/block-categories

MAY 2022

SPECIAL AD SECTION

Protection for All Things Hydraulic, Pneumatic and Fluid Power MOCAP manufactures an extensive range of protective closures to guard pipes, hoses, and hydraulic fittings from dirt, moisture, and damage to help maintain equipment reliability. Included are a variety of sizes and styles of Threaded and Non-Threaded plastic Caps and Plugs for Metric, NPT, BSP, JIC and SAE Threaded Connections, Ports and Fittings. These are in addition to MOCAP’s already extensive lines of low-cost Caps, Plugs, Grips, Netting, Tubing and Tapes for general Product Protection, Finishing and Masking. All of our stocked items are ready for immediate shipment and available in Box, Mini-Pack and Micro-Pack quantities. Free Samples are always available for testing purposes.

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Electric Clutches for Pumps

Ogura produces a wide variety of electric clutches for mobile applications. These clutches provide simple on/off operation for a variety of pumps. Remotely engaging the pump through the clutch reduces drag on engine start-up, increases pump-life and allows multiple pumps to be used off one engine. Various belt types as well as pump shafts can be accommodated. Watch our video on how they work: https://ogura-clutch.com/video-mobile.php

Ogura Industrial Corp. 100 Randolph Road • Somerset, New Jersey 08873 Phone: 732-271-7361 • Fax: 732-271-7580 www.ogura-clutch.com • info@ogura-clutch.com

Slip-In Check Valve Retaining Assembly

Contact us to showcase your products and services in the Product Spotlight. This special section is a high-profile area offering productspecific advertising. Visit fluidpowerjournal.com for more information or to view our media guide.

Genuine Donaldson Internormen-Eaton Velcon-Parker We're hydraulic filter experts. We've been doing it for over 30 years. We're very competitive and happy to serve your needs. If you need hydraulic filter application help, we know the right questions, and we can give you the right answers. J/T Hydraulics & Service Co. Inc. 1601 W. 25th Street • Houston, TX 77008 Local: 713.984.9727 • Toll Free: 800.591.8280 Fax: 713.861.2250 • www.jthydraulics.com

MAY 2022

Inserta® IGSP Slip-In Check Valve Retaining Assembly, Flange Type, provides an effective means to retain an Inserta® IGS Slip-In Check Valve in a 90 degree flow path application (oil inlet-axial, oil outlet-radial). These are available to retain nominal valve sizes from one inch to two inches inclusive, for flows up to 200 gpm, and pressures up to 6000 psi. Inserta® IGS Slip-In Check Valves used with a 90 degree flow path may be considered as potentially more efficient alternatives to typical thread-in cartridge check valves.

Inserta® Products Blue Bell, Pennsylvania USA www.inserta.com

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CONTAMINATION CONTROL

Routine and scheduled maintenance of hydraulic systems are vital to getting the most out of your Hitachi Mining Excavator. While maintenance plays the largest role in the prevention of unnecessary machine downtime, it can also expose the hydraulic system to high levels of contamination rapidly decreasing component longevity. The importance of contamination control is sometimes overlooked when performing maintenance due to incorrect practices being used.

CO U T CO NTA LTIM HE NT M A RO INA TE L T TI OO ON L

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The FlangeLock™ tool and caps are the ultimate contamination control tools for protecting your hydraulic system. The FlangeLock™ allows for the simple sealing of open hydraulic flanges without tools while the caps can be bolted in place of a flange connection. Easy on, easy off, they offer a leak-proof solution to hydraulic systems and environmental cleanliness. FlangeLock™ tools and caps stop the mess.

The FlangeLock™ Tool is the ultimate contamination control tool for protecting HITACHI MAKING systems. CONTAMINATION CONTROL EASY sealing of open SAE code 61, 62 your hydraulic It allows for the simple Hitachi have packaged FlangeLock™ tool and caps specifically for Hitachi mining excavators. The Hitachi customised & CAT-Style hydraulic flanges without tools. Constructed from lightweight aluminum. kits make sure no matter which component routine maintenance is being performed on, you will always have the exact Easyofon, easy off.™*Offers to hydraulic system and environmental and capsatoleakproof help reducesolution contamination. number FlangeLocks cleanliness. FlangeLock™ Tools stop the mess! ™ *Note: FlangeLocks are not to be used under pressure

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Genuine Metaris® Orbital Motors are your best low speed high torque motor option in an economical and compact design. The motors are engineered with Roller-Star technology, come in a range of displacements and we offer multiple flange options including wheel mount. You’ll find that our motors are a perfect fit, form and function replacement for common OEM motors in the market today, such as Eaton®/Char-Lynn®, Danfoss®, Parker® and White®.

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A L L A B O U T VA C U U M

A Quiz on Vacuum Pressure and Forces By Dane Spivak, Engineering Manager, Davasol Inc. In this article, we’ll explain the concept of pressure forces related to vacuum and throw in some quizzes along the way. Keep reading to learn and test your knowledge! Pressure measurement is an important concept in vacuum and fluid power in general. Pressure is defined as the amount force exerted over an area. First, let’s look at the basic principle of pressure by using a typical unit of measurement. Pounds per square inch, or psi, represents an applied force over a single square inch area (1 in2). This is demonstrated in figure 1, in which a two-pound weight sits on a 1-inch × 1-inch square area. Figure 1. In this case, the platform is experiencing 2 psi of pressure as a 2-pound weight is applied to a 1 in2 area, and therefore 2 lbs ÷ 1 in2 = 2 lbs/in2 = 2 psi. Though psi is commonly used for simplicity, the true scientific unit is lbs/in2.

pressure or absolute pressure. On that note, the psi unit can have different notations to indicate the referenced datum point. Psi(a) (where “a” indicates absolute) refers to the true pressure, so at sea level the pressure is 14.7 psi(a). On the other hand, psi(g) (where “g” indicates gauge) is what would be shown on a gauge, which is the differential pressure compared to atmospheric. So at sea level, the pressure is 0 psi(g), which is the same as 14.7 psi(a). Revisiting the inHg and mmHg (Torr) scales, the inHg zero point is at atmospheric pressure, while the Torr zero point is absolute pressure. Figure 2. The two scales are inversely proportional, meaning if one goes up the other goes down. These two measurements have been strategically implemented since inHg would typically be used when trying to understand how much pressure difference there is from atmospheric, while Torr would indicate how close pressure is to absolute pressure or how much actual pressure remains in a volume. Both scales and units are useful depending on the application and expected vacuum level reading.

Question 1. A 5-pound weight

Question 3. Consider atmospheric pressure to be 14.7 psi(a) (0 psi(g)).

sits on a 2-inch diameter platform. What is the pressure in psi that the platform surface experiences? Hint: Circle Area = π r2

Vacuum is applied to a tank and the gauge measures negative 12 psi(g) (2.7 psi(a)). What is the pressure in inHg and Torr? Hint: 1 psi = 2.04 inHg; 1 psi = 51.7 Torr.

Question 1.

of measurement are understood, let's consider a system in which we can take this knowledge and use it in a practical application. Consider the following for question 4 at an atmospheric pressure of 14.7 psi(a) (0 psi(g)). Six identical circular Question 4. vacuum cups with a diameter of 4 inches grip a sheet of glass under a 20 inHg vacuum level. What is the total theoretical gripping force being applied to the glass? Hint: Make sure the units match up before doing your calculations.

Question 2. Conversely, if you have a known pressure applied to an area, the applied force can be calculated. Since we know that pressure is force over area, we can derive that force is pressure multiplied by the area. This is mathematically written as F = P × A. Question 2 gives an example in which a pressure of 10 psi is being applied to a circle with a 4-inch diameter. What is the force being applied to the circle?

Question 2.

In vacuum, pressure units are rarely measured in psi. The commonly used units are inches of mercury (inHg) or millimeters of mercury (mmHg or Torr). These units can describe the same pressures, just like measuring lengths in inches or millimeters. If you know one of the measurements, it can be converted to the other. Figure 2 shows a table of vacuum measurements. There are two important datum points on this scale. The very top, which is atmospheric pressure, and the very bottom, which is zero atmospheric pressure, referred to as absolute pressure. There is nothing lower than absolute pressure; that is the zero point where all air and matter has been removed from a known volume. However, atmospheric pressure varies depending on a number of factors, most notably altitude and weather. Standard sea level pressure on earth is considered 14.7 psi. But at a higher altitude, this number gets lower, so on a mountain the pressure may be 13 psi. This is an important concept in vacuum measurement since, depending on the expected vacuum level, the measurement datum point may come from atmospheric WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Question 4. Now that the concept of vacuum pressure and the units

It is important to note that theoretical calculations should not be considered as a final solution since safety factors should be implemented. In vacuum gripping applications, safety factors are typically anywhere from four to six, though they can climb as high as 12. So if an application requires a safety factor of five to lift a 20-pound weight, the theoretical gripping force should be 100 pounds or higher. Interpreting vacuum level pressures correctly is evidently crucial in calculating the lifting forces correctly. Unlike positive pressures above atmospheric, vacuum pressure has two potential reference points and different units of measurements for that very reason. The added complication is necessary given atmospheric pressure is a variable. This article is intended as an educational guide. Professional assistance should be considered for system designs and solutions. See page 31 for the solutions to the questions above.

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This article is the opinion of the author, Dane Spivak of Davasol Inc., an industrial brand management firm. One of Davasol’s clients, Vacuforce LLC, based in Indianapolis, partners with the author on this article. Contact Dane Spivak at dspivak@davasol.com. MAY 2022

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Solutions to the questions on page 29

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Solution to Question 1

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Area=π r2=π 12=3.14in2 Pressure = weight ÷ area = 5 lbs ÷ 3.14 in2 = 1.6 lbs/in2 = 1.6 psi

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Solution to Question 2 A=π r =π 2 =12.6〖 in Force = Pressure × Area = 10 lbs/in2 × 12.6 in2 = 126 lbs 2

Solution to Question 3

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Pressure in in Hg = 12 psi × (2.04 inHg/psi) = 24.5 inHg Pressure in Torr = 2.7 psi × (51.7 Torr/psi) = 140 Torr

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Solution to Question 4

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Pressure in psi = 20 inHg × (1 psi/2.04 inHg) = 9.8 psi Area=π r2=π 22=12.6 in2 Force = Pressure × Area = 9.8 lbs/in2 × 12.6 in2 = 123 lbs Each cup provides 123 lbs of force multiplied by six cups, which results in a total theoretical lifting force of 738 lbs.

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