Chapter 8

Fluid Storage and Distribution

Reservoirs, Conductors, and Connectors

Objectives
Describe the function of the hydraulic system reservoir and identify the primary design features involved in its construction. Explain the factors that must be considered when establishing the size of a reservoir for use in a system. Describe the factors that are basic to the design and structure of fluid conductors used in hydraulic systems.
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Objectives
Compare and contrast the various types of pipe, tubing, and hose used in hydraulic systems and explain the ratings for each conductor. Identify and explain the factors that must be considered when selecting a conductor for use in a hydraulic system. Explain the information typically found on data sheets provided by the manufacturers of hydraulic system pipe, tubing, and hose.
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Reservoir
The primary purpose of the reservoir is to hold the system fluid not currently in use in the system Other important functions of the reservoir are:
Remove heat Separate solid particles Release air from fluid Separate water from fluid
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Reservoir
The reservoir serves many functions

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Reservoir
The typical hydraulic system reservoir is a rectangular, covered steel tank The tank is typically fitted with:
Pump inlet line System fluid return line Drain line Filler cap Air breather Fluid-level indicator
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Reservoir
Baffles are used in the interior of reservoirs to direct flow to maximize the distance the fluid must travel between the return line and the pump inlet line
Slows the movement of the fluid Increases cooling Increases separation of solid particles, air, and water

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Reservoir
Baffles are typically included in a reservoir

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Reservoir
Typical reservoir construction

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Reservoir
L-shaped and overhead reservoir designs may be used in systems where positive pressure is needed on the pump inlet line

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Reservoir
L-shaped reservoir

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Reservoir
Overhead reservoir

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Reservoir
In special situations, the system reservoir may be:
Cavities in large machines Gear cases in mobile equipment

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Reservoir
As a general rule, the capacity of the reservoir should be three times the rated flow of the pump
Fixed installations may be higher Mobile applications, where weight and space are factors, may be less

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Conductors
The proper selection, installation, and maintenance of conductors is critical to efficient hydraulic system operation

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Conductors
Pipe, tubing, and flexible hose are considered basic conductors in a hydraulic system

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Conductors
Conductors must have:
Adequate strength to withstand high system pressures Low flow resistance to assure low energy loss during system operation A design that allows economic installation and low maintenance

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Conductors
Conductors must not only withstand normal system operating pressure, but also hydraulic shock pressures Shock pressures result from kinetic energy in the system when:
Directional control valves are shifted to reverse the movement of a load or heavy machine member Actuators encounter sudden load changes

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Conductors
Low flow resistance requires a conductor with an inside diameter large enough to allow the needed volume of fluid to move through the line within recommended fluid velocities

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Conductors
Restrictions may cause turbulent flow

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Conductors
Flow resistance in a system results from resistance to fluid flow caused by:
Surface of the conductor Bends and fittings in the lines Orifices in components Turbulence in the fluid stream Viscosity of the fluid

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Conductors
Fluid flow resistance resulting from fluid movement through conductors and other system components:
Lowers the work output of a system Produces heat, which may cause operating problems

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Conductors
Future maintenance must be carefully considered when designing and installing hydraulic system conductors to assure minimal difficulty in removing components for service

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Conductors
Pipe in a hydraulic system should be:
Seamless, black pipe ANSI schedule rating of 40, 80, or 160, depending on the maximum pressure expected in the system

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Conductors
Various nominal pipe dimensions

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Conductors
Schedule number indicates wall thickness

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Conductors
Tubing:
Is a relatively thin-walled, semirigid conductor Can be bent and shaped into lines that provide good flow characteristics with a minimum of visual clutter

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Conductors
Tubing can be bent, unlike pipe

Used with permission of CNH America LLC Goodheart-Willcox Co., Inc.

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Conductors
The size of tubing is indicated by the actual outside diameter
Inside diameter varies according to wall thickness Most tubing is manufactured to the specifications of a standardizing organization such as ANSI or SAE

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Conductors
Hose is a flexible conductor made up of:
Inner tube to conduct the fluid Middle layer of reinforcing material for strength Outer protective coating to withstand abrasion and abuse

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Conductors
Hose with braided-wire middle layers

Gates Corporation

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Conductors
Hose with spiral-wound-wire middle layers

Gates Corporation

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Conductors
Hose provides flexibility

Used with permission of CNH America LLC

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Conductors
A wide variety of hoses are available, often making selection difficult Standardizing organizations provide guidelines that help compare various products on the market

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Conductors
Manifolds are machined or fabricated parts used to distribute system fluid They are often used to help produce a lighter, more-compact system

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Conductors
A wide variety of fittings are available to assist in attaching conductors to system components such as:
Reservoir Pump Valves Actuators

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Conductors
Careful selection of fittings can:
Help control construction costs Improve system efficiency Allow easier system maintenance

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Conductors
Dryseal standard pipe threads should be used on pipe fittings, rather than standard pipe threads, to assure a tight thread seal that will not leak under high system pressure

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Conductors
Standard pipe threads

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Conductors
Dryseal standard pipe threads

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Conductors
Fittings with pipe threads or straight threads sealed with an O-ring or a metal compression washer are typically used to attach tube and hose to hydraulic components Tubing is attached to fittings by flaring the tube, compression, soldering, or brazing

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Conductors
Hose attached to an actuator with elbow fitting and adapter with pipe threads

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Conductors
Hydraulic systems typically use a 37 flare angle

Gates Corporation

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Conductors
Compression fittings use an O-ring, ferrule, sleeve, or patented configuration to provide the seal

Gates Corporation Goodheart-Willcox Co., Inc.

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Conductors
Soldered or brazed fittings usually use split flanges to mount the fitting to the component

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Conductors
Metal hose-end fittings are used to connect flexible hose to the components of the system
Available in both permanently attached or reusable styles Attached to the components using pipe threads, flare fittings, or split flange fittings

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Conductors
Reusable hose-end fittings are either:
Screw-together type Clamp type

These fittings can be assembled to the hose using basic hand tools, which allows field assembly

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Conductors
Permanently attached hose-end fittings are crimped or swaged onto the hose Special equipment is required to install this type of fitting on a hose

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Conductors
Crimped hose-end fittings

Gates Corporation

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Conductors
Swaged hose-end fitting

Gates Corporation

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Conductors
A wide variety of adapter fittings are available for making proper connections between conductors and system components:
Transitions from one thread type to another Elbows at 45 and 90 Swivels that allow component movement

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Analysis of Circuit and System Operation

Properly selecting a conductor requires an examination of not only the hydraulic system, but also the mechanisms operated by the system Factors that must be considered are:
Pressure requirements Flow requirements Vibration Required movements of machine members
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Analysis of Circuit and System Operation

When selecting a conductor for a system, consider pressure:
Normal system operating pressure Shock pressures

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Analysis of Circuit and System Operation

Flow velocity must be carefully considered when selecting a conductor for a system
Pump inlet line average fluid velocity should not exceed 4 ft/sec Working line fluid velocity should not exceed 20 ft/sec

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Analysis of Circuit and System Operation

Low pump inlet velocity prevents excessively low pressure in the line
Too low of a pressure can lead to pump cavitation Cavitation can cause serious pump damage

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Analysis of Circuit and System Operation

Excessively high working line velocity will produce turbulent flow
Turbulent flow can cause high flow resistance High resistance results in increased system operating temperatures

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Analysis of Circuit and System Operation

Very high and very low temperatures can adversely affect the service life of a hose Continuous system operation at or above recommended temperatures can cause damage

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Analysis of Circuit and System Operation

Hose must be rated for the system operating temperature

Used with permission of CNH America LLC

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Interpreting Data Sheets from Manufacturers

Data sheets are available from the conductor manufacturer
Good source of information Include a full range of information about a conductor:
Construction details Typical applications Technical data related to pressure, flow capacity, and temperature tolerance

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Conductor Installation
When installing pipe and tubing, it is important to have the correct lengths
Should not be distorted Should not be placed under tension Distortion and tension can result in material fatigue and lead to part failure

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Conductor Installation
When installing tubing, the number of fittings in a system can be reduced by bending the tube where possible Hand tools and power equipment are available to produce accurate bends

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Conductor Installation
Long lengths of pipe and tubing should be supported by brackets or clamps to secure the conductor This will reduce fatigue caused by conductor weight or system vibration

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Conductor Installation
System pressure changes will change the length and diameter of a hose
Allow slack in the hose Allow adequate hose-to-member clearances

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Conductor Installation
Allow slack in hose when it is installed

Gates Corporation

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Conductor Installation
When hose is installed, ensure it is not twisted

Gates Corporation

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Conductor Installation
When assembling hydraulic system conductors and their associated fittings and adapters, the result should:
Be a neat and uncluttered conductor layout Efficiently distribute fluid throughout the system

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Conductor Installation
A clean and efficient conductor installation

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Review Question
The component that is designed to hold the fluid not currently in use in the system is called the _____. reservoir

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Review Question
What are the two reservoir configurations that are suitable for use with a pump that requires a positive pressure on the inlet line? A. L-shaped and B. overhead

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Review Question
List the three basic categories of fluid conductors used in hydraulic systems.

A. Pipe, B. tubing, and C. flexible hose.

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Review Question
American National Standards Institute (ANSI) schedule numbers identify the _____ of pipes.

wall thickness

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Review Question
List three factors assured by the proper selection and installation of pipe, tube, or hose fittings in hydraulic systems. A. Reasonable initial construction cost, B. efficient system operating, and C. minimal ongoing maintenance.

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Review Question
Name four situations that may result if conductors and fittings are not carefully selected for a given hydraulic system.
A. Conductors may cost more than necessary, B. inefficient system operation, C. parts may prematurely fail, and D. disassembly may be more difficult than necessary during service.

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