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App for rapid configuration and calculation of sub-assemblies
R+L Hydraulics has developed a web app for configuring and calculating hydraulics assemblies. The new program was presented for the first time at this month’s Hannover Messe trade fair. The Fluidware App is an online application for calculating layouts of sub-assemblies, consisting of bell housing, shaft coupling and accessories. Uniting the functions of conventional configuration software with additional design, sales and service functions in a single application, the app can be used either with a web browser on a desktop PC or on a tablet.
PH Crane range from Penny Hydraulics
Penny Hydraulics has launched its new range of fully hydraulic PH Cranes. Introduced to meet the needs of the 1 to 18 tonne UK commercial vehicle market, the range offers over 470 lightweight, user-friendly and innovative models. It has between 0,5 and 5 tm lifting capacity with boom reaches up to 6.83 metres. A variety of optional extras and accessories are available including full stability control, high speed hoists and radio remote controls.
Fluid power increases solar efficiency
Skyfuel inc, of Arvada, Colorado designs and manufactures parabolic trough concentrating solar collectors, to harness solar radiation for the production of steam for utility-grade electricity generation and industrial applications. Crucial to the effective operation of the parabolic trough is the ability to precisely position the concentrator for maximum solar capture as the sun moves across the sky.
Freudenberg introduces new generation of polyurethane
Freudenberg Sealing Technologies has introduced a new generation of polyurethane that is expected to set new standards for the sealing industry. The polyurethane was developed for a wide array of uses and the new standard material is more resistant to water and withstands major temperature fluctuations than existing polyurethanes.
Pall launches Coralon filter element upgrade
Pall Corporation has launched the Coralon hydraulic and lube oil filter element range, a direct upgrade for Pall’s Ultipor and Red1000 series filters. Coralon filter elements incorporate a new medium pack construction that benefits from Stress-Resistant filter medium Technology (SRT) along with other material upgrades to provide improved fluid cleanliness, enhanced fluid cleanliness sustainability, and lower clean pressure drop while providing equivalent service life of its Ultipor predecessor.
Online sealing technology resource centre
A new information hub has been launched to showcase best practice in sealing technology in a bid to provide ‘solutions for tomorrow’s engineering’. The Knowledge Centre by Trelleborg Sealing Solutions aims to bridge the gap between design engineers’ needs and standard technology documentation, bringing useful information together as part of one digital portal.
FluidSafe fluorescent additive saves money by detecting hydraulic fluid leaks early
FluidSafe fluorescent additive from Alerton International quickly detects hydraulic leaks in fluid power system hoses, fittings, seals and other components. This saves money by reducing operating costs. Undetected hydraulic fluid leaks cost the mining industry untold amounts of money. This includes the costs of fluid replacement, problematic system operation, equipment breakdown, fines for environmental contamination, and the possibility of fluid injection injuries to personnel. It has been estimated that in North America alone, over 100 million gallons (380 million litres) of hydraulic fluid could be saved every year if leakage was eliminated. FluidSafe is ideal for preventive maintenance. When used in combination with a SafetyBlu blue light inspection kit or blue lens filter specially designed to fit over a variety of mining lamps, it can easily detect fluid leaks that are usually very hard to find. The exact source of even extremely small leaks is pinpointed by its bright green fluorescent glow. Users have reported a 5% to 7% savings in hydraulic fluid consumption. At $5 per gallon ($1.30 per litre) for hydraulic fluid, these savings are equivalent to $0.25 to $0.35 per gallon (3.8 L) ─ vastly surpassing the cost of FluidSafe. FluidSafe is available in two specially formulated blends to work with both oil-based hydraulic fluids and oil-in-water emulsion hydraulic fluids. www.alertoninternational.com.
$1 million Subsea Well Response Project order for Amarinth
Amarinth – the company specialising in the design, application and manufacture of centrifugal pumps and associated equipment to the Oil & Gas, petrochemical, chemical, industrial and renewable energy markets – has been appointed by Expro to deliver US$1 million of API 610 OH1 pumps for the Subsea Well Response Project.
New hand pump range ‘for every industrial application’
Holmatro is introducing a new series of hand pumps said to be suitable for all industrial applications. The company reports that, from experience, it knows that not all employees treat tools with equal care. This, it adds, is why the new Holmatro hand pumps are very robust. According to Holmatro, the pumps can withstand rough treatment and are not affected by rain or sand. They are also said to be very service- and maintenance-friendly. All technical parts are very accessible and modules can easily be replaced without disassembling the tank.
Poclain launches MI250 large displacement motor
Poclain Hydraulics is turning towards its more demanding markets with a new hydraulic motor that has a maximum displacement of 30 L. According to the company, this product will satisfy its customers’ requirements for reliability and lifespan, while also coming in a compact size.
Subsea high pressure hoses for enhanced safety and increased uptime
Power management company Eaton has launched the Synflex 3395-32 and 3394-32 Thermoplastic Hoses, designed specifically to help increase uptime, safety and reliability for subsea oil and gas applications. The new high pressure hoses are a market exclusive for 2-inch hoses reinforced with Kevlar to withstand the demanding oil and gas industry in a lightweight package. “Uptime is crucial to the success of operations within the critical environments faced by the oil and gas industry each day,” said Ulrich Ammer, product marketing manager at Eaton. “Eaton’s Synflex offering helps keep projects up and running with light weight, durable, Kevlar-reinforced hoses that are safer and easier to handle in even the most challenging environmental conditions.” Light, flexible and buoyant By reinforcing each hose with Kevlar instead of steel wire, this latest Synflex product development is claimed to be considerably lighter, more flexible and more buoyant than competitive steel wire reinforced hoses. At less than 1.4 pounds per foot (lbs/ft.) in air, the 3395-32 weighs in 3 lbs/ft. lighter than steel wire hoses, considerable weight savings when factoring in the thousands of feet required for subsea applications. The weight reduction removes the need for specialty equipment to deploy down and reel up the hose, while making it easier and safer for workers to move or carry. Both the 3395-32 and 3394-32 hoses are built with P40 TL grade nylon core tubes, with two braids of Kevlar aramid fiber reinforcement and jacketed with black polyurethane, which is pin-pricked in accordance with API 17E. The Guardian abrasion protection and patent-pending detection overlay is separated from the base hose by a Mylar film with a linear monofilament to permit gas flow between the hose and the overlay. The 3395-32 hose is rated for 5,000 pounds per square inch (psi) working pressure and a 3-to-1 burst to WP ratio, while the 3394-32 hose is rated for 3750 psi working pressuring with a full API 17E rating and 4-to-1 burst to WP ratio. Both products exceed 200,000 impulse test cycles and can withstand operating temperatures ranging from -40 to 72 degrees Celsius. The hoses are currently available in continuous lengths up to 2500 feet. www.eaton.com/hydraulicsSubsea high pressure hoses for enhanced safety and increased uptime
Power management company Eaton has launched the Synflex 3395-32 and 3394-32 Thermoplastic Hoses, designed specifically to help increase uptime, safety and reliability for subsea oil and gas applications. The new high pressure hoses are a market exclusive for 2-inch hoses reinforced with Kevlar to withstand the demanding oil and gas industry in a lightweight package. “Uptime is crucial to the success of operations within the critical environments faced by the oil and gas industry each day,” said Ulrich Ammer, product marketing manager at Eaton. “Eaton’s Synflex offering helps keep projects up and running with light weight, durable, Kevlar-reinforced hoses that are safer and easier to handle in even the most challenging environmental conditions.” Light, flexible and buoyant By reinforcing each hose with Kevlar instead of steel wire, this latest Synflex product development is claimed to be considerably lighter, more flexible and more buoyant than competitive steel wire reinforced hoses. At less than 1.4 pounds per foot (lbs/ft.) in air, the 3395-32 weighs in 3 lbs/ft. lighter than steel wire hoses, considerable weight savings when factoring in the thousands of feet required for subsea applications. The weight reduction removes the need for specialty equipment to deploy down and reel up the hose, while making it easier and safer for workers to move or carry. Both the 3395-32 and 3394-32 hoses are built with P40 TL grade nylon core tubes, with two braids of Kevlar aramid fiber reinforcement and jacketed with black polyurethane, which is pin-pricked in accordance with API 17E. The Guardian abrasion protection and patent-pending detection overlay is separated from the base hose by a Mylar film with a linear monofilament to permit gas flow between the hose and the overlay. The 3395-32 hose is rated for 5,000 pounds per square inch (psi) working pressure and a 3-to-1 burst to WP ratio, while the 3394-32 hose is rated for 3750 psi working pressuring with a full API 17E rating and 4-to-1 burst to WP ratio. Both products exceed 200,000 impulse test cycles and can withstand operating temperatures ranging from -40 to 72 degrees Celsius. The hoses are currently available in continuous lengths up to 2500 feet. www.eaton.com/hydraulics
What to know about solid contaminants
MP Filtri UK answers some commonly asked questions surrounding solid contaminants and how to keep your hydraulic fluid as clean and efficient as possible. What routines must be followed in order to minimise the chances of my hydraulic equipment suffering costly, premature component failures and unscheduled downtime? Six main routines must be followed: • Maintain fluid cleanliness; ISO 4406 /NAS 1638 etc. • Maintain fluid temperature and viscosity within optimum limits. • Maintain hydraulic system settings to manufacturers' specifications; e.g. ISO/NAS cleanliness for components, pressures etc. • Schedule component change-outs before they fail. Always bear in mind the anticipated life of component. • Follow correct commissioning procedures; including flushing and start-up procedures. • Conduct proactive analysis; regular monitoring, filter replacements, daily/weekly inspections etc. How can I limit solid contamination from entering my system? Good Housekeeping practices are essential. A few steps you can take to make an immediate difference include: • No food and drink near your process. • Pre-filter your new or used oil before placing into or returning back to the tank. • Use a dedicated funnel for that type of fluid for pouring into the tank. • Have a dedicated fill point for the reservoir. • Use a sloped or conical tank design with an outlet at the bottom so that contaminants captured by the first bank of filters • After filling or topping up with new oil, let the system flow and filter, reaching a natural equilibrium point before using live in your process. • Fit good quality breathers that are suitable for the application.3 micron or better. • Regularly replace the breathers, especially in harsh environments. How clean is clean? The answer to this question varies from customer to customer, depending on their requirements and system conditions. What can be said is that the decision to control contamination is normally based on the sensitivity of the components within the process (e.g. servo valves, actuators). There is widely publicised data on the clearances in these types of component and the cleanliness levels required. This information can also be found on the MP Filtri website. One of the main things that is overlooked in the industry is scale of cleanliness we are trying to control and measure. This is important to consider as it may change the way you choose to use your data to get a more realistic picture of system conditions over time. Below is a diagram showing the typical size particles we filter every day and measure with APC’s compared to common objects. It puts into perspective the challenge faced when designing a system. To eliminate all contaminants below a certain size is extremely difficult when you consider all the possible sources of contamination surrounding the system. Care should always be taken to select the right equipment and use suitable statistical methods when evaluating data, making decisions and taking action. What are the predominant types of contamination in my hydraulic system? This can vary considerably depending on the type of system and installation, but below are some typical types of contamination. By looking at the certain types, conclusions can often be drawn as to where the contaminant may be entering the system. Steps can then be taken to reduce the effects of such a contaminant… • Metallic — both ferrous and non-ferrous. • Silica (dirt, dust). • Silt. • Filter fibers. • Bacteria colonies. • Water. What effect does particulate contamination have on my system? Contamination can induce excessive stress on system components like pumps and valves as well as potentially clogging orifices, nozzles, and jets. One of the main areas of degradation is the formation of oxygenated & heavy polymeric compounds. These compounds are often in-soluble and settle out of the fluid as a gel or sludge. The creation of such compounds is accelerated in the presence of water and metal and so care should be taken to remove these types of contaminant from your oil. Typically when a fluid is contaminated its viscosity can vary, leading to higher than normal friction, subsequent temperature increases and loss of lubricity. This can reduce system efficiency, wear components and effect compression rates. In the worst case contamination can lead to catastrophic failure. Below is a list common complaints associated with un-suitable fluid condition: • Mechanical wear. • Clogging of nozzles, orifices and valves. • Corrosion. • Loss of protective coatings on components. • Increased operating temperatures • Change in fluid compressibility. What factors can effect particle distribution & concentration within my system? Unlike laboratory conditions real world applications are constantly changing. As a system operates, contamination is generated and needs to be controlled. As it is physically impossible to achieve 100 per cent efficiency in any given system, some particles will always get through filtration. This is one source of variation. More often than not it is assumed that downstream of any filtering and purification the fluid is ‘clean’ however this may not be the case. As in most hydraulic systems, construction is mainly metal or elastomer/textile based. Over time, and in reaction to changing fluid conditions such as temperature, pressure and chemical decomposition, these materials can become susceptible to corrosion and leach out contaminants into the system. Homogeneity plays a significant part in accurately assessing contamination in a system. A homogenous solution is uniform in its composition and particles are evenly distributed within it. It is fair to conclude that the majority of real world systems are heterogeneous (unevenly composed) and therefore when taking measurements this must be considered as a significant variable between tests. Factors including but not exclusive to viscosity, temperature, electrical conductivity, surface tension can contribute negatively to the overall quality of your fluid. www.mpfiltri.co.ukKeep safe and efficient through hydraulic hose awareness
Chris Buxton, CEO of the British Fluid Power Association (BFPA), and Martin Kingsbury, the BFPA’s membership director, consider some important safety and efficiency aspects to be aware of when sourcing, fitting, using, maintaining and replacing hydraulic hoses. As any engineering professional knows, hydraulic hoses have an invaluable part to play in the efficient running of many types of industrial and mobile plant. For example, they are often used for the supply of oil under pressure for motion control in high-powered machinery such as cranes, excavators and extruder equipment. If they are supplied to the user or OEM to the correct specifications, and installed in accordance with current guidelines, they will likely operate reliably and efficiently. It is worth mentioning, however, that because of the wide range of hydraulic hoses available for different applications – articulated, coiled, corrugated, reinforced etc. – it is important to bear in mind a number of valuable points in order for your equipment to suffer minimal downtime and be safe for the operators and maintenance engineers. Avoiding fluid injection injury When dealing with hose assembly providers, it is important to be as sure as possible that you are sourcing high-quality hose, fittings and related equipment and services. This is not just a requirement from an efficiency and reliability point of view, but also from health & safety perspective. High-pressure injection injuries as a result of a faulty hydraulic hose are comparatively rare; occurring in an average of 1 in 600 cases of hospital reported hand injuries. However, when they do occur they should be taken very seriously indeed and treated as a medical emergency. And it’s not only the injured individual whose health can be seriously affected; the question of professional responsibility, accountability and reputation of the company can also be raised. In the worst-case scenarios, where a fatality occurs, there could even be a level of managerial culpability that leads to prosecution under the Corporate Manslaughter Act. The right specification So, what can be done to substantially mitigate any risk of hose failure, or, at worst, the scenario of a burst hose that results in a fluid injection injury to users or maintenance personnel? One practice to avoid is the mixing of different suppliers’ fittings for use in the same hydraulic hose application. Not all providers supply the same sizes, thread forms or taper angles, even though two different fittings may look more or less the same. Fittings have thread sizes that are often measured using a number of different formats, such as metric, BSP and MPT. Therefore if size and thread form information etc. is not written on the fitting, it is highly advisable that you seek the guidance of someone who is capable of using a thread gauge because the thread form must be known before it is installed. It is also important to tighten a hydraulic fitting to the torsion level specified by the manufacturer or supplier. Qualified fitters know that more torque doesn’t necessarily mean more oil tightness. Moreover, too much torque can end up damaging the fitting’s thread, making it difficult to unscrew and potentially reducing its efficiency and lifespan. Also, some hydraulic fittings tighten against a locking ring, clamping ring, taper or a soft seal, so if the fitting is over-tightened the rings or seals could become distorted – and this in turn can lead to a faster rate or corrosion or wear. Appropriate material Hydraulic hose fittings are made of different materials for use in specific environments. There are two most commonly used types of material. One is carbon steel, cast, forged or fully machined and often with either a zinc- or chrome-type plating. The next most common material used in the manufacture of hydraulic fittings is stainless steel – most commonly 316 in ‘open air’ or non-corrosive environments, and alternatives such as 318 in more corrosive environments such as in marine or medical installations. With this in mind, it is important always to consider the most appropriate material for a particular application. Additionally, it is inadvisable to mix fittings with different material specifications. By using fittings made of different materials on the same hose application corrosion may occur more easily, and this could result in leaks further down the line even though the hose application might seem to work efficiently to being with. Lifespan Bear in mind also that hydraulic hoses are not permanent. A variety of factors can impact the lifespan of a hydraulic hose. Flexing the hose too much, twisting it, kinking, stretching, crushing or scratching the surface can reduce hose life. Too low or too high operating temperatures will break down hoses as will sudden sharp rises or drops in internal pressures. Using the wrong size, type or weight of hoses can also cause hoses to break down. Hoses should be replaced before they fail; especially when used with hydraulic heavy machinery, brakes or safety-critical hydraulic machinery. Hoses show swelling, cracking, blisters and bubbles when worn or may show virtually no signs at all. Replace hoses as often as recommended by the manufacturer to prevent accidents. Raising awareness The British Fluid Power Association (BFPA) has established a number of programmes aimed at raising the awareness levels of people who work with hydraulic hose at all levels; from the system designer and field engineer, to the machine operator and the person who makes the hose: The BFPA’s ‘Foundation Course in Working Safely with Hydraulic Hose and Connectors’ is an accredited and certified course aimed at personnel who are involved in manufacturing and installation of hydraulic hose assemblies and connectors. The one-day course comprises a classroom-training period, followed by a practical session on the manufacture of a range of hose assemblies and pressure testing procedures. The BFPA’s practical, workshop-based course titled ‘The BFPA Hose Assembly Skills Training Programme’ follows in logical succession to the Association’s Foundation Course. The Skills Course takes this basic level of knowledge and trains to a fully assessed level of ability in hose assembly techniques. This two-day course covers the various theoretical and practical elements involved in working with hose and connectors. During the course the candidate is trained to an assessed level of ability in working with hose and connectors. The BFPA recently introduced a new practical, workshop-based course titled ‘The BFPA Hose Integrity, Inspection and Management Training Programme’. Following in logical succession to the Association’s complementary ‘Foundation’ and ‘Skills’ courses’, this course builds upon the knowledge already gained, extending it into management-related areas such as inspection, analysis, identification, registering and recording of hydraulic hose and related equipment. Key themes covered during the one-day course include: hose life expectancy; risk analysis; competence by way of a robust competence assurance system; identify, inspect & record; hose register – recording of a hose assembly prior to it going into service; and visual hose assembly (installation) inspection check list. Reputable providers Do not trust your equipment to anyone other than a reputable hose equipment provider; whether the company in question is a member of the BFPA Hose Accreditation Scheme, a holder of the BFPDA Approved Hose Assembly Mark or runs a rigorous and reputable scheme of its own. And, in terms of hose training, make sure the provider’s courses are well-established and highly respected within the hydraulics industry; whether they run their own courses or are authorised agents for the BFPA’s own Hose Foundation, Hose Skills and Hose Integrity, Inspection and Management Training courses. When it comes to hose and fittings, don’t accept anything but equipment of a high quality. After all, when the efficiency of your plant and equipment, as well as the health & safety of your workforce is at stake, only the best product, training and service provision is acceptable. The subject of hydraulic fluid injection injury is covered in the above-mentioned BFPA training courses. The BFPA has also published a booklet titled ‘Fluid Injection Injury Emergency – The Facts’, priced at £3.30 for BFPA/BFPDA members and £6.60 for non-members. If you would like more information about the BFPA courses, booklet, authorised training bodies, the BFPA’s Hose Accreditation Scheme or BFPDA Approved Hose Assembly Mark, please contact the BFPA on 01608 647900 or email: enquiries@bfpa.co.uk. More information is available on the Association’s website: www.bfpa.co.uk. For course-specific information, please also visit: www.bfpatrainingacademy.co.uk.Technical advice is crucial when choosing a hose reel
By Michael Pawson, managing director, ReCoila,
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