Hydraulics and Pneumatics (Subject Code BMT403)

ACHARYA INSTITUTE OF TECHNOLOGY ENGALURU-560107

Department of Mechatronics Engineering.

Hydraulics and Pneumatics Laboratory Manual

BMT 403

Prepared by,
Mr. Naveen Kumar S N
Assistant Professor
Department of Mechatronics Engineering

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Hydraulics and Pneumatics (Subject Code BMT403)

INDEX

SI. Page
Name of the Experiment CO
No No.
1. To determine the performance of reciprocating hydraulic
pump.
2. To determine the performance of Centrifugal hydraulic
pump.
3. To control speed of single acting cylinder actuation on
Hydraulic/Pneumatic Trainer
4. To control speed of double acting cylinder actuation on
Hydraulic/Pneumatic Trainer
5. To develop sequencing circuit on Hydraulic/Pneumatic
Trainer
6. To develop regenerative circuit on Hydraulic/Pneumatic
Trainer
7. To design and analysis of Hydraulic Synchronizing circuit
using Software (like SIMULINK)
8. To design and analysis of Hydraulic Regenerative Circuit
using Software (like SIMULINK)
9. To design and analysis of pneumatic circuits using
Software (like SIMULINK)
10. To Demonstrate the working of air compressor.
11. To Demonstrate the working of air compressor.
12. To demonstration of working of different types of valves.
13. To demonstration of working of solenoids.

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Hydraulics and Pneumatics (Subject Code BMT403)

Experiment 1: CENTRIFUGAL PUMP TEST RIG

AIM: To conduct performance test on centrifugal pump.

EXPERIMENTAL SETUP: Centrifugal Pump test rig, Stop Watch.

THEORY:

➢ The pump which converts mechanical energy into pressure energy by means of
centrifugal force acting on the fluid is called centrifugal pump.
➢ The centrifugal pump is an outward radial flow turbomachine. This means that the
flow in pump is in the radial outward direction.
➢ The centrifugal pump works on the principle of forced vertex flow which
means that when acertain mass of liquid is rotated by an external torque, the
rise in pressure head of the rotatingliquid takes place.
➢ The rise in pressure head at any point of the rotating liquid is proportional to the
square of tangential velocity of the liquid at that point. Thus, at the outlet of the
impeller, where radius is more, the rise in pressure head will be more and the
liquid will be discharged at the outlet with a high pressure head.
➢ It can handle large quantity of liquid, so it is meant for large discharge through
smaller heads in case of single stage. But for multi stage construction the pressure
gradually builds up in successive stages almost equally in each stage, thus
achieving considerably higher heads.
➢ The discharge is continuous and smooth. It can be used for lifting highly viscous
liquids. Cost of centrifugal pump is less compared to reciprocating pump. It needs
smaller floor area and installation cost is low.
➢ It has nearly 100% volumetric efficiency, but energy conversion efficiency is low.
➢ The term Net Positive Suction Head (NPSH) is very commonly used in the pump
industry. Actually, the minimum suction conditions are more frequently specified
in terms of NPSH.
➢ Net Positive Suction Head defined as the difference between the pump’s inlet
stagnation pressure head and the vapor pressure head. Where stagnation
pressure head is sum of static (absolute) pressure head and velocity head. In order
to have cavitation free operation of pump, the available NPSH should be greater
than the required NPSH.

PROCEDURE:

1. Fill the air vessels and the sump tank with clean water, keep the delivery valve open.
2. Select the desired speed by adjusting the step cone pulley- motor base handle.
3. Switch on the pump, water starts flowing to the measuring tank.

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Hydraulics and Pneumatics (Subject Code BMT403)

4. Note down the pressure gauge, vacuum gauge reading and time for number of
revolutions of energy meter disc at full opening of delivery valve.

5. Operate the butterfly valve to note down the piezometer reading against the time and
keep it open when the readings are not taken.

6. Repeat the experiment either for different openings of delivery valve or for different
speeds and note down the readings as above.

7. After the experiment is over switch off the mains and keep the delivery and suction
valves fully open.

OBSERVATIONS:
1. Measuring tank area, AT = 0.25 m2
2. Energy meter constant, EMC = 750 rev/kW-h
3. Motor efficiency, ηmotor = 80%
4. Transmission efficiency ηtrans=80%
5. Number of Energy meter rotation (K)=
6. Time taken for Energy meter reading (T)=
7. Time taken for measuring tank reading t =
8. Density of water, ρw = 1000 kg/m3

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 Hydraulics and Pneumatics (Subject Code BMT403)

TABULAR COLUMN:

Energy meter Piezometer reading for

Delivery 10cm water rise, (hw/t)
Suction reading for Kdisc
Pump rev., incm/s
Pressure, Ps Pressure, pd
Sl. Speed, N
No. (RPM) (mm of Hg) (kg/cm2) (K/T) in rev/s

CALCULATIONS:

1. Electrical power input or input to motor in kW:

Wele = [(K/T)/ EMC]×3600

2. Suction Head Hs in m of Water:

Hs= [(Ps × 13.6 /1000)]

3. Delivery Head Hd in m of water:

Hd =Pd ×10

4. Head developed in m of water:

HT =[Hs+Hd]
5. Actual discharge in m3/s:
Qa = AT×(hw /t)
Where A in m2
(hw/t) in m/s
6. Shaft power or input power to pump in kW:
Wi/p=Wsft = Wele × ηmotor

7. Hydraulic power output from pump in kW:

Wop = (ρgQaHT)/1000

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Hydraulics and Pneumatics (Subject Code BMT403)

8. Pump efficiency or mechanical efficiency:

ηmech or ηpump = (Wop / Wi/p)×100

9. Overall efficiency:
ηoverall = ηpump × ηmotor × ηtransmission

FINAL TABULATION:

HT Wele
Sl.
Wi/p Wop ηpump ηoverall
No. (m) (kW)

GRAPH:

1. Head v/s Discharge

2. Electrical power input v/s Discharge
3. Overall efficiency v/s Discharge

RESULT:
The mechanical efficiency of the Centrifugal pump is=……………… at delivery
head………….

Date: Signature of the staff in-charge

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Hydraulics and Pneumatics (Subject Code BMT403)

Experiment : 02

Title : RECIPROCATING PUMP TEST RIG

AIM: To conduct performance test on Reciprocating pump.

EXPERIMENTAL SETUP: The pump test rig is a self contained unit operated on
closed circuit basis. The pump, electric motor, collecting tank, sump tank, and control
panel are arranged with the following provisions:

1. For conducting the experiment at various speeds used stepped pulley arrangement.
2. For measuring the input power to the pump by kilowatt-hour meter.
3. For recording the RPM using digital RPM indicator.
4. For recording pressure and vacuum.
5. For changing the pressure (delivery head) and vacuum (suction head) by
operating the control valve.
6. For measuring the discharge by piezometer.

THEORY:
➢ The hydraulic machines which convert the mechanical energy in to hydraulic
energy are called pumps. The hydraulic energy is in the form of pressure energy.
➢ If the energy conversion occurs by sucking the liquid into a cylinder in which a
piston is reciprocating, which exerts the thrust on the liquid and increases its
hydraulic energy, the pump is known as reciprocating pump.
➢ It mainly consists of a piston reciprocating inside a cylinder thus performing suction
and delivery strokes so it is also known as positive displacement machine.
➢ If the water is in contact with one side of the piston, the pump is known as single-
acting pump and if the water is in contact with both sides of the piston, the pump
is called double-acting.
➢ Slip of a pump is defined as the difference between the theoretical discharge and
actual dischargeof the pump. If actual discharge is more than the theoretical
discharge, the slip of the pump will become negative. Negative slip occurs when
delivery pipe is short, suction pipe is long and pumpis running at high speed.
➢ FroFIt handles small quantity of liquid only, so it is meant for small discharge and
high heads. The discharge is fluctuating and pulsating. It is used only for lifting pure
water or less viscous liquids.
➢ Cost of reciprocating pump is approximately four times the cost of centrifugal
pump. It requires large floor area, so installation cost is high and due to
reciprocating parts maintenance cost is more.
➢ It is having high energy conversion efficiency, but volumetric efficiency is low.
➢ Generally these pumps are used for feeding small boilers, for lifting water to a
higher heads and pumping light oil.

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Hydraulics and Pneumatics (Subject Code BMT403)

PROCEDURE:
1. Fill the air vessels and the sump tank with clean water, keep the delivery valve open.
2. Select the desired speed by adjusting the step cone pulley- motor base handle.
3. Switch on the pump, water starts flowing to the measuring tank.
4. Note down the pressure gauge, vacuum gauge reading and time for
number of revolutions ofenergy meter disc at full opening of delivery valve.
5. Operate the butterfly valve to note down the piezometer reading against the
time and keep it openwhen the readings are not taken.
6. Repeat the experiment either for different openings of delivery valve or for
different speeds andnote down the readings as above.
7. After the experiment is over switch off the mains and keep the delivery and
suction valves fullyopen.

OBSERVATION:
1. Measuring tank area, AT = 0.12 m2
2. Diameter of Pistion D= 55mm.
3. Length of Stroke L= 40mm.
4. Energy meter constant, EMC = 750 rev/kW-h
5. Number of Energy meter rotation (K)=
6. Time taken for Energy meter reading (T)=
7. Time taken for measuring tank readine t =
8. Motor efficiency, ηmotor = 70%
9. Density of water, ρw = 1000 kg/m3

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 Hydraulics and Pneumatics (Subject Code BMT403)

TABULAR COLUMN:

Delivery Energy meter

Suction reading for K
Pump Pressure, Ps Piezometer reading
Pressure, pd disc rev.,
Sl. Speed, N for 10cm water
No. (RPM) (mm of Hg) (kg/cm2) (K/T) in rev/s rise, (hw/t) in cm/s

CALCULATIONS:

1. Electrical power input or input to motor in kW:

Wele = [(K/T)/ EMC]×3600

2. Suction Head Hs in m of Water:

Hs= [(Ps × 13.6 /1000)]

3. Delivery Head Hd in m of water:

Hd =Pd ×10

4. Head developed in m of water:

HT =[Hs+Hd]

5. Theoritical Discharge in m3/s:

Qt = LAN/60

6. Actual discharge in m3/s:

Qa = AT×(hw /t)

Where A in m2
(hw/t) in m/s
7. Shaft power or input power to pump in kW:
Wsft = Wele × ηmotor Fro

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 Hydraulics and Pneumatics (Subject Code BMT403)

8. Hydraulic power output from pump in kW:

Wop = (ρgQaHT)/1000

9. Pump efficiency or mechanical efficiency:

ηmech or ηpump = (Wop / Wip)×100

10. Overall efficiency:

ηoverall = ηpump × ηmotor

11. Slip = [(Qt - Qa) × 100] / Qt

FINAL TABULATION:

HT Qt Qa Wele
Sl.
(m3/s) Wip Wop ηpump ηoverall Slip
No. (m) (m3/s) (kW)

GRAPH:

1. Head v/s Discharge

2. Electrical power input v/s Discharge
3. Overall efficiency v/s Discharge

RESULT:
The % slip of of the Reciprocating pump is=………………at delivery head……………

Date: Signature of the staff in-charge

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Hydraulics and Pneumatics (Subject Code BMT403)

EXPERIMENT NO: 03

STUDY OF SPEED CONTROL CIRCUIT ON PNEMATIC TRAINER

(Single acting cylinder)
Speed control during a work stroke can be accomplished by regulating flow to the
cylinder. The check valve allows free reverse flow when the cylinder retracts. It
normally gives finer speed control than a meter-out circuit. Regulating flow from the
cylinder is another way to control speed. This circuit maintains a constant backpressure
during rod extension and prevents lunging if the load drops quickly or reverses.

Figure: Bleed-off circuits: (a) Bleed-off for both directions and (b) bleed-off for inlet to the
cylinder or motor.

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Hydraulics and Pneumatics (Subject Code BMT403)

Flow to the cylinder is regulated by metering part of the pump flow to tank. This circuit is
more efficient than meter-in or meter-out, as pump output is only high enough to overcome
resistance. However, it does not compensate for pump slip.

Fig: Speed control circuit of pneumatic single acting cylinder

Variable-volume pump

Pump flow can be controlled by various means such as manual, electric motor, hydraulic,
or mechanical. How closely flow output actually matches command depends, in part, on
slip, which increases with load. With a pressure-compensated, variable-volume pump,
output flow decreases with the increasing pressure. This type of pump can be used for
traverse and clamp operations. An external relief valve is usually unnecessary when a
pressure-compensated pump is used.

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Hydraulics and Pneumatics (Subject Code BMT403)

Figure: Variable-volume pump

Variable feed

Many machines require intermittent fast and slow feed during their cycles. This can be
accomplished by having a cam-operated 2-way valve in parallel with a meter-out flow
control valve. Rapid forward movement takes place any time the 2-way valve is open.
Closing off the valve slows down cylinder speed. Properly positioning the cams obtains
the required speeds in sequence. The check valve in parallel with the flow control permits
free return flow, allowing the cylinder rod to return rapidly.

Figure: Variable feed

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Hydraulics and Pneumatics (Subject Code BMT403)

STUDY OF SPEED CONTROL CIRCUIT ON PNEMATIC TRAINER

(DOUBLE ACTING CYLINDER)

Fig: Speed control circuit of pneumatic double acting cylinder with 3/2 valve.

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Hydraulics and Pneumatics (Subject Code BMT403)

EXPERIMENT NO: 04

STUDY OF SEQUENCING CIRCUIT ON PNEUMATIC TRAINER

Sequence valves

Cylinders may be sequenced by restricting flow to one cylinder. One method of restricting
flow is with backpressure check valves. They prevent flow until a set pressure is reached.
In this circuit, cylinder 1 extends and retracts ahead of cylinder 2.

Several cylinders can be connected to move in sequence on forward and return strokes.
In this circuit, a clamp must close before a drill descends. On the return stroke, the drill
must pull out of the work before the clamp opens. The sequence valves are arranged to
cause pressure buildup when one cylinder completes its stroke, the valve opens to allow
flow to the other cylinder.

Figure 7.1: Sequencing circuit with solenoid valve.

Figure 7.2: Internally piloted sequence valve

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Hydraulics and Pneumatics (Subject Code BMT403)

Figure 7.3: Sequencing circuit.

Figure 7.4: Representation of pneumatic limits: (a) pressurizes when struck; (b)
vents when struck. (c), (d) show limits which are struck in the rest state

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Hydraulics and Pneumatics (Subject Code BMT403)

Figure 7.5: Sequencing circuit using limits

Sequences are driven by limit switches which pass, or block or vent pneumatic pressure.
On circuit diagrams limit switches are normally shown in the rest (normally unstruck) state.
Figure 8.4a thus vents when unstruck and passes pressure when struck. Figure 8.4b passes
pressure when unstruck and vents when struck.

If a limit is struck in the rest state (for example, the back-retracted state for a cylinder) it is
represented by Figure 8.4c or d. Note the different spool positions between the two sets of
symbols a,b and c,d. The position of limits is normally shown on a circuit diagram by filled
black squares. A simple example of a pneumatic sequencing system is illustrated in Figure
8.5, where the cylinder oscillates continuously between two striker-operated limit switches
a0 and a1. The two limits shift the spool of the valve to extend and retract the cylinder.

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Figure: Sequencing of double acting cylinder circuit

Electrical control

Limit switches momentarily actuated by the cylinders control the solenoid valves to
sequence this circuit. Solenoid is energized by a pushbutton to initiate movement 1. At the
completion of movement 1, limit switch E is actuated to energize solenoid c, initiating
movement 2. At the end of movement 2, limit switch F is actuated to energize solenoid b,
initiating movement 3. At the end of this movement, limit switch G is actuated to energize
solenoid d, initiating movement 4. The sequence valves prevent a pressure drop in either
cylinder while the other operates.

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Hydraulics and Pneumatics (Subject Code BMT403)

EXPERIMENT NO. 05
STUDY OF SYNCHRONIZING CIRCUIT ON PNEUMATIC TRAINER

An effective flow divider can be made up of two fluid motors of the same size coupled
together. Both motors must rotate at the same speed and, therefore, deliver equal volumes
of fluid. Variations in load or friction do not greatly affect synchronization, but motor slip
is a factor.

One of the considerations in synchronizing cylinders is leakage replacement. Under normal

pressure, leakage can be practically zero over one stroke. Accumulated error is the main
concern. A replenishing circuit, which replaces leakage after each cylinder stroke,
eliminates this trend. In the circuit, the cylinders are connected in series and controlled by
the 4-way manual valve. The cylinders actuate limit switches, which control valves A and
B. On the return stroke, if cylinder 1 bottoms first, valve A is actuated to open valve C,
permitting excess fluid from cylinder 2 to flow to tank. If cylinder 2's piston returns first,
valve B is actuated to direct fluid to retract cylinder 1.

Figure: Cylinders in parallel and series.

Rack and pinion

Mechanically tying two cylinders together by installing a rack on each piston rod and
fastening the pinions to a single shaft works well when the linkage is rigid and the mesh
is proper. A chain and sprocket arrangement can be used if synchronized motion is
required in only one direction.

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Hydraulics and Pneumatics (Subject Code BMT403)

EXPERIMENT NO.06
STUDY OF REGENERATIVE CIRCUIT ON HYDRAULIC TRAINER
Rapid rod extension can be achieved by returning the flow of oil from a cylinder's head
end back into its cap end. With no load, pressure in both head and cap ends is equal, so
when the load is encountered, available working force depends on the differential area

Combining the rapid extension of Circuit 1 with full force in response to an applied load
takes full advantage of a regenerative circuit. This circuit produces a rapid approach stroke
of the piston. When the rod encounters resistance (workpiece load), pressure rises on the
cap end to open the sequence valve and allow oil from the head end to flow to tank through
the 4-way valve. Once this occurs, full effective force on the workpiece becomes available.

Instead of a sequence and built-in check, an orifice and check are used. There is some
backpressure remaining in the cylinder's head end because of the orifice resistance during
final squeeze. But with the cylinder extended, no fluid flows across the orifice, so total
available force acts on the cap end. Whether or not this circuit is appropriate for a given
application depends on working force requirements.

Figure: Regenerative Circuit.

When electrical control is desired, a limit or proximity switch can be used to activate and
de-activate a regenerative circuit. In the circuit shown, energizing solenoids a andb extends
the cylinder in a differential circuit. The limit switch de-energizes solenoid b, directing
cylinder discharge fluid to tank.

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Viva voce
1. Define ideal fluid?
2. Define steady flow?
3. What is Coefficient of velocity of venturimeter?
4. What are the components of pneumatic trainer circuit?
5. What is synchronized operation of cylinders?
6. What is a nozzle?
7. What is cavitation?
8. Define ideal fluid?
9. What are the components of Francis turbine?
10. What is calibration?
11. What is kinematic viscosity?
12. What is reaction turbine?
13. What is compounding?

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