H Y D R AU L I C S AND P N E U M AT I CS

UNIT-5 ELECTRICAL AND

ELECTRONIC CONTROL OF FLUID
POWER CIRCUITS
H Y D R AU L I C S AND P N E U M AT I CS
UNIT-5 ELECTRICAL AND
ELECTRONIC CONTROL OF FLUID
POWER CIRCUITS
 ELECTRICAL CONTROL DEVICES:
Electrical control devices are widely preferred because of the following reasons:

(i) They can be easily controlled

(ii)They improve the overall control flexibility of the fluid power systems
(iii)They provide quick and accurate control operations
(iv)They require less maintenance
(v)They exhibit better reliability and have longer service life.
The most commonly used Electrical control devices are :
1. Push-button switches,
2. Limit switches,
3. Pressure switches,
4. Temperature switches,
5. Solenoids,
6. Relays, and
7. Timers.
 1. Push-button Switches
 The push-button switches are primarily used for starting and stopping
of the machinery.
They also provide manual operation when an emergency arises.
The push-button switches are also called as 'momentary switches',
because they make or break contact only as long as they are held under
pressure.
Types:
The four commonly used types of push-button switches are :
(i) Single-pole single-throw - Normally open type (SPST-NO),
(ii) Single-pole, single-throw - Normally close type (SPST-NC),
(iii) Double-pole single-throw type (DPST), and
(iv) Double-pole double-throw type (DPDT).
Fig.14.1 shows the symbolic representation for the above types of push-button switches.

 As shown in Figs. 14.1(a) and (b), the single-pole single-throw type has one normally
open and one normally closed pair of contacts.
 As shown in Figs. 14.1(c) and (d), the double-pole double-throw arrangement has two
pairs of normally open and two pairs of normally closed contacts to allow the
inverting of two circuits with single input.
 2. Limit Switches

• The limit switches are used to identify the extreme limits of the
cylinder actuation.
• Difference: The difference between the push-button and limit switches
is that the push-button switches are actuated manually whereas the limit
switches are mechanically actuated devices.
• Types: Fig.14.2 shows the graphic symbols for the commonly used limit
switches.

Roller Plunger
Limit Switch
In Fig.14.2(a), LS-NO means a limit- Fig.14.3 shows a hydraulic cylinder
that has built-in limit switches, one
switch normally-open.
at each end of the cylinder.
Fig.14.2(b) shows a normally open
limit-switch that is held closed.
There are many operators available
In Fig.14.2(c), LS-NC means a limit-
such as cams, levers, rollers, and
switch normally-closed.
plungers to mechanically actuate
Fig.14.2(d) shows a normally closed
the limit switches.
type limit-switch that is held open.
 3. Pressure Switches
 The pressure switches are used to sense a change in pressure automatically, and
opens or closes an electrical switch when a predetermined pressure is reached.
 They have usually two pressure settings, namely high and low pressure.
 For example, in a circuit it may be required to stop a pump to maintain a given
pressure.
 In this circuit, the low-pressure setting will start the pump and the high-pressure setting
will stop the pump.
• Fig.14.4 shows the graphic symbols used for pressure switches.

 Fig.14.4(a) shows a normally open pressure

switch, which is abbreviated PS-NO.
 Fig.14.4(b) depicts a pressure switch which
is normally closed.
The electrical switch opens and closes at a specific
pressure often referred to as the Setpoint.
 4. Temperature Switches
 The temperature switches are used to sense a change in temperature automatically,
and opens or closes an electrical switch when a predetermined temperature is reached.
 Like other switches, these switches are also wired either normally open or normally
closed.
 Fig.14.5 shows the graphic symbols used for temperature switches.
 Fig.14.5(a) shows a normally open type temperature switch and Fig.14.5(b) shows the
normally closed type.
 5. Solenoids
 A solenoid is an electromagnetic mechanical transducer that converts an electrical
signal into a mechanical output force.
 Solenoids provide a push or pull force to remotely operate fluid power valves.
 Fig.14.6(a)'shows the graphical symbol used to represent the solenoid

An indicator lamp is used to indicate

the state of a specific circuit
components.

Fig.14.6(b) shows the symbolic representation of an indicator lamp.

• Indicator lamps are used :

(i) to identify which solenoid operator of a DC valve is energized, and
(ii) to indicate whether a hydraulic cylinder is extending or retracting.
 Small Push-Pull Solenoid - 12VDC

A solenoid is a cylindrical coiled wire that acts as a magnetic field

when it carries electric current and creates an electrical signal.
 6. Relays
 The electrical relays offer simple ON/OFF switching action in response to a signal
issued by a control system.
 In other words, relays are nothing but electrically operated switches.
 Relays are commonly used to open or close the contacts and thereby energize or de-
energize solenoids which operate at a high current level.
 A low-voltage circuit can be used to energize relay coils that control high-voltage
contacts used to open and close circuits containing the solenoids.
 Operating Principle:
Fig.14.7(a) illustrates the operating principle of an electrically operated relay switch.

Fig.14.7(b) shows
the graphical
symbols for the
relay coil and the
symbols for the
normally open and
closed contacts.

 When switch 1-SW is closed, the current flows through the coil of wire and thus a
magnetic field is produced.
 This pulls a spring-loaded moveable relay arm that forces the contacts to open or
close.
 Usually there are two sets of contacts with upper one being normally closed (NC)
contacts, and the lower one is normally open (NO) contacts.
 7. Timers or Time-Delay Relays

Timers, also known as time-delay relays, are time delay switches used
to control the time duration of a working cycle.
Timers are commonly applied in electrical control circuits when a time
delay from the instant of actuation to the closing of contacts is
required.
These timers can be adjusted to change the dwell period for many
machining operations.
For example, in a drilling machine operation the timers provide a
dwell, which allows the drill to pause for a predetermined time at the
end of the stroke to remove the chips.
The main difference is that normal relays switch from a normally close terminal to a
The symbolic representation of the timers is shown in Fig.14.8
normally open terminal immediately whereas in time delay relays the contacts are closed
or open only after a preset time interval.
 Fig.14.8(a) shows a normally open switch when energized closes after a
predetermined time interval.
 Fig.14.8(b) shows a normally closed timer switch that is time opened when energized.
 Fig.14.8(c) shows the normally open timer switch that is timed when de-energized.
 Fig.14.8(d) shows the normally closed timer switch that is time closed when de-
energized.
 LADDER DIAGRAMS
 It should be noted that while drawing any electrohydraulic (or electropneumatic)
circuits, separate circuits should be drawn for the fluid system and the electrical
system.
 Also each components should be labeled so that one can understand exactly how the
two systems interfaced.
 The second circuit showing the electrical system is known as ladder diagram.
 Thus the operation of the total system can be understood by examination of both the
fluid power circuit and ladder diagram (i.e., electrical circuit).
 A ladder diagram is a representation of hardware connections between switches,
relays, solenoids, etc., which constitute the basic components of an electrical
control system.
 In other words, a ladder diagram is nothing but an electrical diagram showing the
hardware connections between the various electrical control devices.
 Details of a Ladder Diagram
Consider a typical ladder diagram as shown in Fig.14.9 for some application.

• Legs and Rungs: In Fig.14.9, the

two vertical electrical power supply
lines are called 'legs', and the
horizontal lines containing
electrical components are called
'rungs'.

 In ladder diagrams, always the power is connected to the left leg and the ground is
connected to the right leg.
 It should be noted that always the switches should be shown in their unactuated (i.e.,
open) mode in the ladder diagrams.
 Since the electric circuit diagram resembles to a ladder, this diagram is called a
'ladder diagram'.
Uses:
Ladder diagrams provide a circuit designer with a practical means to
examine input process and output functions to quickly plan the
circuit layout design for a particular hydraulic or pneumatic
application
 ELECTRO HYDRAULIC/PNEUMATIC CIRCUITS
While drawing electro hydraulic/pneumatic circuits, both electrical
systems and hydraulic/pneumatic systems can be shown parallel.
(i) Continuous Cylinder Reciprocation using Pressure Switch

Figure 5.19: Continuous

cylinder reciprocation using
pressure switch

 In this circuit, normally open pressure switches are used to control the systems as
shown in figure 5.19.
 When the switch I-SW is closed, the cylinder reciprocates continuously until I-SW is
opened.
(i) Continuous Cylinder Reciprocation using Pressure Switch

Figure 5.19: Continuous

cylinder reciprocation
using pressure switch

The sequence of operation is as follows:

 Assume solenoid A last energized and thus the cylinder is in fully extended position.
 When I-SW is closed, the pressure builds up to actuate the pressure switch 1-PS and
energizes the solenoid B to shift the valve.
 Now, the pump is turned on and oil flows from the pump to the rod end of the cylinder.
 When the cylinder is retracted fully, the pressure will build up to actuate 2-PS pressure
switch.
 In the mean times, I-PS has been de actuated to de energize SOL B.
 The closing of contacts of 2- PS energizes solenoid A to begin once again the extending
stroke of the cylinder and thus the hydraulic cylinder is continuously reciprocating.
 (ii) Cylinder Control using Limit Switches
Figure 5.20 shows the substitute of pressure switches to control the operation
of double acting hydraulic cylinder. It is very similar to the previous circuit in
which the pressure switch is replacing limit switch (Normally open).

Figure 5.20: Cylinder control

using limit switches

 Assume solenoid B is last energized and thus the cylinder is in fully retracted
position.
 At this position, it actuate the limit switch l-LS and thus solenoid A is energized.
 Hence, the oil flows from the pump to the blank end of the cylinder and thus
cylinder extends.
 When the cylinder is in fully extended position, it actuate the limit switch 2-LS
and thus solenoid B is energized.
 Thus the flow goes to the rod end of the cylinder to retract the piston.
 (iii) Control of a Cylinder using a Single Limit Switch
Figure 5.21 shows the control of double acting hydraulic cylinder using single solenoid
valve and a single limit switch
 When the START button
is momentarily pressed,
the cylinder extends as
coil 1-CR is energized,
which closes both sets of
contacts of 1-CR.
 Thus, the upper l-CR set
of contacts serves to keep
coil l-CR energized even Figure 5.21: Cylinder control using single limit switch
though the start button is
released.

 The lower set of contacts closes the energize solenoids A to extend the cylinder
 When 1-LS is actuated by the piston rod, it opens to de energize coil-CR.
 This reopens the contacts of 1-CR to de energize the solenoid A.
 The valve returns to the spring-offset mode to retract the cylinder.
 This closes the contacts of I-LS, but coil l-CR is not energized because the
contacts of l-CR and the START button have return to their normally open
position.
 It stops the cylinder movement however the cycle repeats when each time
the START button is momentarily pressed.
 The STOP button is actually a panic button which is pressed to retract the
cylinder instantly while extending.
 (iv) Dual Cylinder Sequence Circuits
Figure 5.22 shows an electro pneumatic circuit for the sequence operation of two cylinders.

Figure 5.22: Dual-Cylinder

Sequencing Circuit
 When the START button is momentarily pressed, SOL A is momentarily energized to
shift valve V1 to extend the cylinder 1.
 When 1-LS is actuated, SOL C is energized which shifts valve V2 into its left flow path
mode.
 This extends cylinder 2 until it actuates 2-LS. As a result, SOL B is energized to shift V1
into its right flow path mode.
 As cylinder 1begins to retract, it de actuates 1-LS which de energizes SOL C.
 The valve V2 comes into spring offset mode and cylinder 1and 2 retracts together and
thus the cycle is Completed.
 (v) Dual Cylinder Sequence Circuit using Relay Contacts
Figure 5.23 shows the dual cylinder sequencing circuit using relay contacts.

Figure 5.23: Dual

cylinder sequencing
circuit using relays

 When the start button is pressed momentarily, contact relay 1-CR gets energized which in
turn energizes the solenoid A to allow the flow from pump to the blank end of the
cylinder
 through valve V1.
 Hence the cylinder extends, Actuation of limit switch 1-LS, de energizes the solenoid A
and energizes the solenoid B.
 The limit switch 1-LS used here is a double pole single throw switch.
 It actuation opens the holding circuit for relay 1-CR and simultaneously closes the
holding circuit for relay2-CR.
 This returns valve V1 to its spring offset mode and switches valve V2 into its solenoid
actuated mode and hence cylinder I retracts and cylinder 2 extends.
 When 2-LS are actuated, solenoid B is de-energized to return valve V2 to its spring offset
mode to retract cylinder 2.
 Stop button pressing retracts both cylinders instantly.
 (vi) Electrical Control of Regenerative Circuit
Figure 5.24 depicts the electrical control of regenerative circuit. A regenerative circuit
speeds up the extending operation of a hydraulic cylinder. When switch l-SW is
manually placed into the extend position, solenoid A gets energized and extends the
cylinder.

Figure 5.24:
Electrical Control
of Regenerative
Circuit

 When extending, oil from the cylinder rod pass joins to the incoming oil from the
pump through check valve V3 to provide rapid extension of cylinder.
 On extending, oil pressure builds up to close the pressure switch 1-PS and thus blocks
the flow until the desired pressure is reached.
 This energizes the coil-CR and solenoid C to vent the oil from rod end directly back to
the reservoir through valve V2 thus the cylinder extends slowly as it drives the load.
 Electrical Control of Regenerative Circuit

Figure 5.24:
Electrical Control
of Regenerative
Circuit

 Relay coil 1-CR holds the solenoid C as energized during the slow extension of the
cylinder to prevent any fluttering of the pressure switch.
 This would occur because fluid pressure drops at the cylinder blank end at the
completion of regenerative cycle and switch the pressure switch 1-PS to energize and
de-energize continuously.
 When the switch l-SW is placed in the retract position solenoid B becomes energized
and de energizing 1-CR and solenoid C. Thus cylinder is retracted in the normal
fashion.
 When the switch l-SW is put into the unload position, all the solenoids and the relay
coils are de energized and returns the valve V1 in its spring centered position to
 PLC Applications in Fluid Power Control
 The main function of controller is used to execute an efficient control
sequence by using logically developed processing sequences.
 This control in a proper sequence has traditionally been performed by timers,
switches, relays, counters, and similar hard-wired devices based on
mechanical, electromechanical, and pneumatic principles.
 In 1968, PLCs were introduced to replace these hardwired devices. PLCs are
made from primary digital modules such as counters, registers and memory
and arithmetic units along with a small instruction set suitable for industrial
control applications.
 PLCs are similar to computers but computers are optimized for calculation
and display task.
 PLCs are optimized for control tasks and the industries environment.
 Features of Programmable Logic Controller (PLC)

PLC's offers the following features:

1. Rugged in construction.
2. Faster in response time
3. Easily programmed in an understandable way.
4. PLCs can replace hundreds a relays and occupy significantly less
space.
5. The circuit logic can be easily altered without rewiring.
6. It has no moving parts or contacts to wear out.
7. The implementation is flexible and scalable.
8. They can operate in the adverse condition of the factory floor
especially with increased temperature and humidity.
 Definition of PLC

Figure 5.25 shows

the basic Structure
of a PLC

Figure 5.25: Programmable logic controller

Programmable Logic Controller (PLC) is a specially designed digital

operating microprocessor-based controller that uses a
programmable memory for internal storage of instructing and for
implementing functions such as logic, sequencing, timing, counting
and arithmetic in order to control machines and processes.
Basic Components of a PLC
PLC consists of three basic components as shown in figure 5.26. These are
1) Central Processing Unit (CPU)
2) Programming device
3) Input / Output modules (I /O M)

Figure 5.26: Elements of PLC

 Central Processing Unit:
Like computer, the CPU is said to be the heart of the PLC.
The CPU controls and processes all the operations within the PLC.
It processes the signals received from input module and generates
controlling signals for the system.
The information carried within the PLC is carried by means of digital
signals.
It consists of the following units:

Arithmetic and Logic Unit (ALU):

This unit performs data manipulation and arithmetic and logical operations
on input variable data and determines the proper state of the output
variables.
The arithmetic operation includes addition, subtraction etc., and logical
operations include AND, OR, NOT and Exclusive - OR.
Memory Unit:
The memory unit contains the program stored in it.
These programs were written with the control actions to be executed by the
microprocessor for the given input.
During entering and editing including debugging, the program is stored in the
temporary storages called Random Access Memory (RAM).
Once the program completely finished (free from errors), it may be burned
into a ROM.
When the ROM is plugged into the PLC, the device is ready to place into a
service in the industrial environment.
Memory may be either volatile type or non-volatile type.
 1. Volatile Memory
 Volatile memory or temporary memory or Application memory is the user memory, where the
user can enter and edit the program.
 Shortly, it stores the data files and programs that can be altered by the user.
 Volatile memory will lose all its programmed contents if operating power is removed or lost.
 It is therefore, necessary to provide a battery backup power to all times.
 One type of volatile memory is RAM, Random Access Memory, which moves Read / Write
memory.
 Information stored in RAM can be retrieved or "read". "Write" indicates that the program can
be developed or written into the memory by the user.
 "Random Access" refers to the ability of any locations in the memory to be accessed or used.

2.Non-Volatile Memory
 Non-volatile memory or permanent memory or system memory is (used as)a system memory that
stores the monitor or booting programs.
 This is usually programmed and supplied by its manufacturer.
 This controls the operation of PLC.
 It does not loses its content during power failure. Hence, it does not require any battery.
 The ROM memory offers the CPU to use only fixed amount of data.
 The different types of ROMs are
 1. PROM - Programmable Read Only Memory (cannot be altered).
 2. EPROM - Erasable Programmable Read Only Memory (Altered by erasing with UV light
source).
 3. EEPROM - Electrically Erasable Programmable Read Only Memory (Erases by electrical
signals).
Programming Device:
 The programming device is used to enter the required program into the memory of the CPU.
 The program is first developed in the programming device and transferred them into the
memory unit.
 Shortly, the programming unit allows the programmer to enter and edit the program to be
executed.
 Programming device may be either in a simple form or advanced system
 In its simplest form, it can be a hand-held device with a keyboard for a program entry and a
display device (LED) for viewing the program steps.
 Advanced system uses a common I/O unit as a personal computer to write, view and edit the
program .
 A major advantage of using a computer is that the program can be stored on the hard disk or a
floppy disk and copies easily made.
 The disadvantage is that the programming often tends to be not so user friendly.
 Hand-held programming consoles will normally contain enough memory to allow the unit to
retain programs while being carried from one place to another.
Input/output Modules:
 The input modules receive information from external devices and send to
processor and communicate the processed information to the external devices
through output modules.
 The input devices are mechanical switches, photo sensors, temperature
sensors, flow sensors, other type of sensors, keypads etc,
 The output device may include solenoid valves, relays, contactors, lights, horns,
heating elements, fans, motor starter, signal amplifiers, conveyor belt, lift,
automatic door etc.,
 I/O devices are also called peripheral devices.
 The input signal should be low level dc logic voltage.
 In case, the input voltage is A.C, a bridge rectifier, converts the A.C to D.C and
resistors drops the voltage to the required level.
 If D.C, only resistors are used to drop the voltage.
PLC Operation:
When the power is supplied to a PLC, the operation is not simultaneous for the entire
ladder diagram and is not continuous as there is a time delay to scan every input.
The PLC operation consists of two modes.
1) Update inputs and outputs termed as I/O scan mode.
2) Solve the ladder called as program scan mode or Execution mode.

I/O Scan Mode:

 During this mode, the processor updates all the Inputs and outputs.
 The time required for this depends on the processor speed.
 I/O updating means that all input states are recorded from the input unit and all
output states are transferred to the output unit.
 This accomplished by using I/O image registers placed aside in the PLC memory
by specific address.
Program Scan Mode:
 During this mode, the PLC starts executing the commands in the user program.
 The processor evaluates each rung of the ladder diagram program that is being
executed sequentially, starting from first rung and proceeding to the last rung.
 As a rung is evaluated, the last known state of each switch and relay contact in
the rung is considered, and if any TRUE to the output device is detected, then the
output is indicated to be energized - i.e., set to ON.
 At the end of the ladder diagram, the I/O mode is entered again, and all output
devices are provided with the ON/OFF state determined from execution of the
ladder diagram program.
 All inputs are sampled, and the execution mode starts again.
 PLC Programming (Ladder diagram)
 The programming commonly used with PLCs is ladder programming.
 This involves each program task being specified as through a rung of a ladder.
 Thus such a rung could specify that the state of switches A and B, the inputs, be examined
and if A and B both are closed then a solenoid, the output is energized and vice versa.
 The sequence followed by a PLC when carrying out a program can be as follows:

Figure 5.28. Ladder diagram

Figure 5.27: Program sequence
Fluid Power Circuit

A+B+B-A-

Figure 5.29 Fluid Power Circuit for two cylinder sequence operation

X- Input port address

M- Marker coil/Relay address
Y- Output port of O/p module

Figure 5.30: Ladder diagram

 MAINTAINING OF FLUIDS
 Hydraulic fluids are the life blood of the hydraulic system.
 The hydraulic fluid transmits pressure and energy, seals close-clearance
parts against leakage, minimizes wear and friction, removes heat, flushes
away dirt and wear particles, and protects surfaces against rusting.
 Conventional petroleum (mineral) oils are normally used in hydraulic
systems, but fire-resistant, synthetic, and biodegradable fluids are used in
other situations.
 There are four key objectives that are essential to gaining optimum service
life of hydraulic fluids:
Control the Temperature
Keep Systems Clean
Keep the Fluid Clean
Keep an Oil Analysis Program
 (i) Control the Temperature
 Heat develops in the fluid as it is forced through the pumps, motor tubing, and
relief valves.
 Excessive temperatures will oxidize the oil and can lead to varnish and sludge
deposits in the system. Conversely, running the temperature too low will allow
condensation in the reservoir and increase the likelihood of pump cavitation.
 Typical industrial hydraulic system temperatures often range between 110 to
150ºF.
 Keep systems which operate on a water-based fluid below 140ºF to prevent the
water from evaporating.
 The deposits caused by oil degradation can plug valves and suction screens and
cause high-tolerance servo valves to seize and/or operate sluggishly.
 In modern equipment using servo valves, oil degradation can be even more
damaging.
 High pressure (up to 4000 psi), high temperatures, and small reservoirs stress the
fluid. With minimal residence time and high pressures, entrained air bubbles can
cause extreme localized heating of the hydraulic fluid.
 This results in nitrogen fixation that, when combined with oil oxidation, can
form deposits which will plug oil filters and cause servo valves to stick.
 (ii) Keep Systems Clean

 Even new systems may be contaminated and should be cleaned

before use.
 Prevent contaminants such as dirt, water, cutting fluids, and metal
particles from entering the system around the reservoir cover,
openings for suction and drain lines, through breather fill openings,
past piston rod packing, and through leaks in pump suction lines.
 (iii) Keep the Fluid Clean
 Keeping hydraulic fluids clean begins with good storage and handling
practices.
 To prevent contamination before use, store new fluid in a protected area and
dispense it in clean, DEDICATED containers. Clean the fill cap before
removing it to add hydraulic fluid.
 On critical NC systems, use quick disconnect hoses and filter all oil added to
the reservoir through a 5 micron filter.
 Full-flow filters designed into the system keep the fluid clean while in service.
 Inspect fluid filters frequently and change or clean them before they go into
bypass mode.
 Portable filters will supplement permanently installed filters and should be
constantly rotated from system to system regardless if you think the system
requires filtering or not.
 Systems should be filtered long enough to pass the total volume of oil through
the filter at least 10 times.
 Portable filters should be used when transferring new oil from drums or
storage tank to a system — especially for NC machines.
 (iv) Keep an Oil Analysis Program
 OEM’s generally specify that system hydraulic oil be drained annually.
 However, with an effective oil analysis program, you can safely increase
that interval while at the same time provide yourself with an “early
warning” of possible mechanical problems.
 At minimum, check your critical and large volume hydraulic systems at
least annually by oil analysis.
 Semi-annual or even quarterly sampling intervals may be required for
extremely critical machines.
 Consult lubrication engineer and machine OEM for the best sampling
interval and the parameters to be tested.
 HYDRAULIC SYSTEM CARE
 Hydraulic system maintenance is just as important, and directly related to,
hydraulic oil maintenance.
 All the filtering and analysis done on a hydraulic oil would be meaningless
and futile if the system itself is in a shambles.
A 10 Point Check:
1. Check fluid levels 6. Visually inspect the inside of the reservoir
for signs of aeration (via the fill hole using a
flashlight)
2. Inspect breather caps, breather filters and 7. Listen to the pump for the signs of
fill screen. cavitation.
3. Check filter indicators and/or pressure 8. Inspect a small sample of fluid for colour,
differential gages. signs of contamination and odour.
4. Visually inspect all system hoses, pipes, 9. Scan electrically controlled servo valves
pipe connections for leaks and frays. with an infrared thermometer.
5. Check system temperature via built-in 10. Scan the electric drive motor with for
thermometers or hand-held infrared housing hot spots and rotor bearing
detectors. temperatures using an infrared thermometer.
 Fluid Change-Out Recommendations:
These are the proper steps to follow when changing the hydraulic fluid in a
system.
1. Drain the system while the fluid is hot to keep contaminants in
suspension.
2. Empty fluid from cylinders, accumulators and lines that might not drain
properly.
3. Mop, siphon, or pump out oil left in the reservoir.
4. Wipe reservoir clean with lint free rags and remove rust and free paint.
5. Replace or clean filter elements and strainers and clean filter housings.
6. Refill the system with new fluid making sure to vent high points.
7. Restart and check system for proper operation.
 DISPOSAL OF HYDRAULIC FLUID

 Hydraulic fluid can pose significant environmental risks if not handled

and disposed of correctly.
 It contains chemicals that can contaminate soil and water, potentially
leading to severe ecological damage.
 Mineral-based fluids, often petroleum-derived, can persist in the
environment and cause long-term contamination.
 Synthetic fluids, while sometimes less harmful, can still pose
significant risks if they contain additives and other chemicals.
 Even biodegradable hydraulic fluids, designed to break down more
quickly, can harm the environment if not disposed of properly.
 The improper disposal of hydraulic fluid can lead to groundwater
contamination, soil degradation, and harm to aquatic life.
 Proper Disposal of Hydraulic Fluid
 Disposal of hydraulic fluid involves several steps to ensure it is done safely
and in an eco-friendly manner.
1. Identify and Label - Clearly identify and label containers of used hydraulic
fluid as hazardous waste. Use leak-proof, sealed containers (typically drums)
to prevent spills. Don’t put two or more different types of fluid in the same
container.
2. Storage - Store used hydraulic fluid in a designated, secure area away from
incompatible substances. Ensure that storage containers are regularly
inspected for leaks or damage.
3. Collection - Small quantities of hydraulic fluid can be taken to local
household hazardous waste collection sites or authorised fluid collection
centres. For larger quantities, engage a licensed hazardous waste disposal
service.
4. Transport - Transport hydraulic fluid in secure, labeled containers to prevent
leaks and spills during transit. Ensure that transport complies with all relevant
regulations,possible,
 Whenever includingyou
proper documentation
should and use fluid
recycle hydraulic of licensed carriers.
for use in future
applications.
 Although it’s not always a viable solution (particularly for fluids with
complex additives), recycling can be a highly effective way of minimising the
amount of waste that can impact the environment.
 OSHA and Safety Standards:
 OSHA (Occupational Safety and Health Administration), a U.S. federal
agency under the Department of Labor. Its primary mission is to ensure safe
and healthy working conditions for employees by setting and enforcing
standards, providing training and education, and collaborating with
employers and employees to prevent workplace injuries and illnesses.
 OSHA and other safety standards address hazards associated with hydraulic
fluids, including chemical exposure, potential injuries from high-pressure
leaks, and the need for proper lockout/tagout procedures.
 Key aspects include ensuring safe working practices, using appropriate PPE,
and implementing measures to control exposure to hydraulic fluids, especially
mineral oil mists.
 Pressurized nature of hydraulic systems presents a range of hazards that can
lead to severe injuries or even fatalities if not correctly managed.
 What are Common Hydraulic System Hazards?
(i) Hydraulic Fluid Leaks:
 A leak in the hydraulic lines or components can result in dangerous fluid
spraying under high pressure.
 Injury Risk: The high-pressure fluid can cause serious hydraulic injuries,
including lacerations, punctures, and even amputation if it comes into contact
with skin. Fluid injected under the skin can be particularly dangerous and
lead to severe tissue damage.
(ii) Hydraulic System Failure:
Hydraulic system failures are a significant safety concern.
These systems rely on a delicate balance of pressure, fluid flow, and
component integrity.
If any of these elements fail, the results can be catastrophic. For instance:
Sudden Pressure Loss: A pressure drop in the system can lead to equipment
malfunctions, such as dropped loads from cranes or lifting equipment,
causing injury to workers.
Over-Pressure Situations: Conversely, excessive pressure can cause the
system to rupture, spraying hot, pressurized fluid and damaging equipment or
posing injury risks to nearby personnel.
 What are Common Hydraulic System Hazards?
(iii) Pinch Points and Moving Parts:
 Hydraulic machinery often includes components like cylinders, pistons, and
actuators that move with high force.
 Workers who are not cautious can become caught in pinch points between
moving parts, leading to crushing injuries.
 Additionally, there is a risk of entanglement with hoses, cables, or other
system parts.
(iv) Incorrect Maintenance and System Setup:
 Hydraulic systems require regular inspection, maintenance, and calibration to
ensure they function safely and effectively.
 Improper installation, failure to address wear and tear, or incorrect repair
work can result in faulty systems, increasing the likelihood of leaks, failures,
and accidents.
(v) High-Pressure Fluid Exposure:
 The high pressure at which hydraulic systems operate can turn even small
leaks into a serious hazard.
 Inhaling or coming into contact with fine mist from leaking hydraulic fluid
can cause respiratory issues, skin irritation, or chemical burns.
 The fluid may also contaminate the environment if not properly contained.
 How to Keep Workers Safe?
(i) Proper Training and Education:
 The first step in ensuring worker safety is to provide adequate training on
hydraulic system hazards and safe work practices.
 Workers should understand how hydraulic systems operate, how to identify
hazards and the importance of using protective gear.
 Key training points should include:
• Recognizing signs of leaks or system malfunction.
• Proper ways to shut down and isolate hydraulic systems during
maintenance.
• Procedures for responding to hydraulic accidents, such as fluid injection or
system failure.
(ii) Use of Personal Protective Equipment (PPE):
 Adequate PPE is critical for anyone working with hydraulic systems.
 Essential items include:
• High-pressure fluid-resistant gloves to protect hands from potential fluid
leaks.
• Face shields or goggles to safeguard eyes from high-pressure sprays or
flying debris.
• Protective clothing, such as long-sleeve shirts and pants, to prevent fluid
from coming into direct contact with skin.
 How to Keep Workers Safe?
(iii) Regular Inspection and Maintenance:
 Preventive maintenance is key to reducing the risk of hydraulic system failures.
 Implementing a routine inspection schedule for hydraulic equipment can help
identify early signs of wear, leaks, or other issues.
 Workers should also be trained to inspect hoses, seals, and fittings for damage
or signs of wear.
 Specific maintenance practices include:
• Checking the system’s pressure regularly to ensure it stays within safe
operating limits.
• Ensuring that hydraulic fluid is free from contamination.
• Replacing worn-out or damaged components before they fail.
(iv) System Design and Safety Features:
 Incorporating safety features into hydraulic system designs can help prevent
accidents. For example:
• Pressure relief valves can help regulate system pressure and prevent over-
pressurization.
• Automatic shut-off valves can quickly isolate leaking or damaged sections of the
system, limiting the spread of hazards.
• Hose guards and protective barriers can be used to shield workers from dangers
of hydraulic fluid spray and moving parts.
 How to Keep Workers Safe?
(v) Clear Communication and Safety Protocols:
 Ensuring workers have clear communication during hydraulic system
operations is crucial.
 This includes using warning signs, labels, and lockout/tagout (LOTO)
procedures when performing maintenance on hydraulic equipment.
 Clear protocols for responding to leaks, injuries, or system failures should
be established, and all workers should be familiar with emergency
response plans.
(vi) Emergency Response Plan:
 Having a well-defined emergency response plan is essential in case of a
hydraulic system malfunction or accident.
 This includes having first aid kits, fire extinguishers, and eyewash stations
readily available.
 Additionally, workers should be trained on how to respond to specific
incidents, such as:
• Hydraulic fluid injection: Immediate medical attention is necessary to
prevent infection or tissue damage.
• Fire: Know the location of fire suppression equipment and have
procedures in place to evacuate the area safely.