General Hydraulics

1. General Hydraulics Fluid Mechanics

2. Different types of drives Packed Plunger Mechanical Diaphragm Hydraulic Diaphragm

3. Mechanically-Actuated Diaphragm Advantages: - Lower cost due to simpler construction - Ease of diaphragm replacement - Sealless design - no fugitive emissions - No possibility of cross-contamination of hydraulic fluid and chemical Disadvantages: - Lower pressure ratings (max <200 psig) - Lower repeatability (< +/- 2%) Reciprocating Shaft Diaphragm with Steel Core

4. Packed Plunger Flush Connector Plunger Advantages: - High pressure capabilities (4600 psig) - Greater repeatability (< +/- 0.5%) Disadvantages: - Fugitive emissions may escape through packing Packing

5. Hydraulically-Driven Diaphragm Advantages: - Higher pressure capabilities - Sealless design - no fugitive emissions - Greater repeatability (< +/- 0.5%) Disadvantages: - Possibility of cross-contamination of hydraulic fluid and chemical - Higher cost due to complexity of design - Difficulty of diaphragm replacement and balancing of hydraulic fluid Air Bleed / Pressure Relief Valve Diaphragm Piston Make-Up Valve Hydraulic Fluid Reservoir Valve Actuator

6. MF MH PS DR

7. Diaphragm type Mf Hydraulically actuated diaphragm head. A double PTFE diaphragm hermetically separates the liquid end from the hydraulic chamber

8. Highlights Mf • hermetically sealed • pressure up to 630 bar (9,135 psig) • temperature range – 40 °C • to + 160 °C (- 40 °F to 320 °F) • PTFE double diaphragm • suction lift up to 8 m (26 ft) • Due to the mechanical rod attached to the diaphragm • accuracy ± 05 % • diaphragm failure indication

9. Diaphragm type Mh Hydraulically actuated diaphragm head. A metal diaphragm hermetically separates the liquid end from the hydraulic chamber similar to the ProMus pump

10. Mh Highlights: hermetically sealed pressure up to 4000 bar (58,000 psig) temperature range – 60 °C to + 160 °C (- 76 °F to 320 °F) accuracy ± 0.5 % diaphragm failure indication

11. Plunger type PS Plunger head with stuff box packing. The plunger oscillates in the cylinder to displace the liquid.

12. PS Highlights: best hydraulic efficiency pressure up to 1000 bar (14,500 psig) temperature range – 40 °C to + 400 °C (- 40 °F752 °F) accuracy ± 0.5 % easy to maintain by central packing adjustment

13. Valveless metering pump DR Valveless operating metering pump with a control piston. It works by the combined oscillating and rotating movement of the piston. Valves are not required. The pump can be operated through a wide range of stroke frequencies.

14. DR Highlights: valveless viscosity up to 1,000,000 mPas (1,000,000 cps) pressure up to 630 bar (9135 psig) temperature range – 40 °C to + 400 °C (- 40 °F to 752 °F) accuracy ± 0.5 % wide range of stroke frequency

15. ProMus • Hydraulically Actuated Diaphragm • Flows to 101 gph • Pressures to 3500 Psi • Cast Iron Drive Case • Liquid End Materials • Stainless Steel • Hastelloy C • Alloy 20 • Easy Field Maintenance

16. The internal components of a ProMus pump

18. Replenishment Circuit Relief Poppet Replenishment Valve Plunger Replenishment Check

19. Replenishment Check Prevents hydraulic oil from returning back to the drive case

20. Replenishment Valve Small amounts of hydraulic oil that is lost due to normal air bleed needs to be replenished. The valve is depressed by the diaphragm and admits hydraulic oil on the suction stroke.

21. Air Bleed Poppet/Relief Valve Allows air to be purged from the hydraulic oil. It checks in both suction and discharge stroke.

23. Oil Lubrication/Hydraulic flow

24. Size 17

25. Size 30

26. Size 40

27. What Can Go Wrong ??

28. Diaphragm Rupture Manually over priming the hydraulics This is usually caused when manually over priming the hydraulics after a diaphragm replacement. All of the air is displaced with hydraulic fluid “ballooning” the diaphragm towards the liquid end and you re-insert the internal relief poppet without loosening the internal relief adjusting screw.

29. If diaphragms keep rupturing towards the liquid end after continuous normal running. Check the replenishment valve for sticking open. Problem Area

30. Hydraulic Shock When there is a pulsation dampener at the discharge and the pressure is increased above the operating pressure causing the internal relief to lift, All of the hydraulic fluid behind the diaphragm is safely dumped back to the drive case. The stored energy from the pulse dampener causes a hydraulic shock until the valve balls seat firmly. This causes the diaphragm to collapse against the contour plate until the pump is out of relief. With the pump running in relief can cause the diaphragm to dimple and or rupture depending on the amount of time and pressure. it’s recommended to replace the diaphragm if running in relief for 24 Hrs.

31. Over heating or lack of lubrication This can be caused from A. diaphragm rupture and product leaking into the drive case displacing the oil. B. Improper maintenance and oil level to low C. Chemical attack

32. Loss of Flow or Pressure?

33. Normal air bleed Like a heart beat

34. Either the Poppet is bad or the pump is running in relief Problem Area Loss of flow or pressure check sight tube

35. Can't get the hydraulic system primed or loss of prime?

36. No Heart Beat or loss of visible fluid flow

37. Loss of hydraulic prime or visible flow Check the inlet filter for being clogged Problem Area

38. The End