Design of Hydraulic & Pneumatic Valves

Lecture 12

Dr. Mokhtar Amrani

Valves are essential parts of hydraulic and pneumatic systems. They are mainly used to control the
flow and pressure of any piping system, whether that is oil, gas, liquid or vapors. Depending on the
valve function, its operation may be manually initiated or may be automatically initiated by a signal
from a control device, or the valve may be automatically respond to changing system conditions.

Pneumatic and hydraulic systems require control valves to direct and regulate the flow of fluid from
compressor or pump to the various load devices. Although there are significant practical differences
between pneumatic and hydraulic devices (mainly arising from differences in operating pressures and
types of seals needed for gas or liquid) the operating principles and descriptions are very similar.

Valves can be broadly categorized based on their function as:

1) stop (isolation) valves.
2) Controlling Valves.
Most Control Valves in Hydraulic and
3) Back-Flow prevention Valves
Pneumatic Systems have Four Ports.
4) Pressure-Relief Valves.

Although valves are used for many purposes, there are essentially only two types of valve. An infinite
position valve can take up any position between open and closed and, consequently, can be used to
modulate flow or pressure. Relief valves are simple infinite position valves.

Most control valves, however, are only used to allow or block flow of fluid. Such valves are called
finite position valves. An analogy between the two types of valve is the comparison between an
electric light dimmer (‫ )ضوء السيارة الصغير‬and a simple on/off switch.

Connections to a valve are termed 'ports'. A simple on/off valve therefore has two ports. Most control
valves, however, have four ports shown in hydraulic and pneumatic forms in Figure 4.1.

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In both the load is connected to ports labeled A, B and the pressure supply (from pump or
compressor) to port P In the hydraulic valve, fluid is returned to the tank from port T. In the pneumatic
valve return air is vented from port R.

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 Various Types of Hydraulic finite position valves

Figure 4.2 shows internal operation of valves. To extend the ram, ports P and B are connected to
deliver fluid and ports A and T connected to return fluid. To retract the ram, ports P and A are
connected to deliver fluid and ports B and T to return fluid.

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 Classification of Control Valves based on No. of ports and positions
Another consideration is the number of control positions. Finite position valves are commonly
described as a port/position valve where, port is the number of ports and position is the number of
positions. However, The numbers of ports and positions does not, however, completely describe the
valve. We must also describe its action. Therefore, Symbolic description is the common one.

a) 2-Way, 2-Position Valve Hydraulic and pneumatic systems have symbols

similar to the electrical and electronic systems.

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b) 3-Way, 2-position Valve

Three-way valves have three pipe connections and two orifices. When one orifice is open, the other
is closed, and vice versa. They are commonly used to alternately apply pressure to and exhaust
pressure from a valve actuator or a single-acting cylinder.

Normally Closed (NC) When the valve is de-energized, the pressure port is closed and the exhaust
port is connected to the cylinder port. When the valve is energized, the exhaust port is closed and the
pressure port is connected to the cylinder port.

3-way, direct-acting, solenoid-operated directional valve

Normally Open (NO) When the valve is de-energized, the pressure port is connected to the cylinder
port and the exhaust port is closed. When the valve is energized, the pressure port is closed and the
cylinder port is connected to the exhaust port.

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An example of hydraulic system in two positions

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 Spool type Directional control valve
In a four way, three position valve, the spool is in one of three positions and there are 4 inlet/outlet
ports in the valve. In the mid-stroke position there is no flow through the valve. A good application of a
4/3 valve is actuator control, where the actuator control goal is to extend, retract or hold a position.
4/3 valves are used in servovalves, where the spool is controlled by a flapper valve or a jet pipe
valve.

c) 4 way 3 positions control valve

First position where the handle at the center. Both upward ports A, B are tightly closed by the 2
pistons in the cylinder. the fluid from the pump are closed for the two downward direction. Therefore,
this position is adjusted when no flow is required.

in neutral position the oil is slightly pass the blockage and return back to the tank. But at the same
time the blockage is completely block the port A & B so there's no oil coming into port A.

Symbolic Representation.

The middle disconnection means that no flow connection between inlet and exit ports. The left side
means flow from pump to pump and no circuit is running. The right side means no flow from the
upward ports.

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Second Position: spool are at extreme right side . The pistons accordingly move from the upper
ports slightly to the right and flow is on.

Flow from pump at port P go through port B at the top, while the discharge from A back to the
reservoir from port T as shown in Figure.

Symbolic Representation

P is connected to B and

A is connected to T . Circuit is running in one direction

Third Position: spool are at extreme left side . The pistons accordingly move from the upper ports
to the left and flow is on but in opposite direction.

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Flow from pump at port P go through port A at the top, while the discharge from B back to the
reservoir from port T as shown in Figure. The flow direction is reversed.

Symbolic Representation

P is connected to A and

B is connected to T . Circuit is running in the opposite direction to the second position.

If the spool is at the home position (The 4 ports are blocked) there is no narrow leakage from P to
Tank. because every hydraulic systems have a pressure relief valve, when the spool is at the
middle and the system pressure is getting high due to no flow from the direction control valve. So the
relief valve will open; hence the fluid returns to Tank.

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Example of hydraulic system is the Hydraulic Ram of The Crane.

This is one practical example of 4 ports 3 position control valve. The cylinder on the upper side is
working in opposite direction for each cycle, which in turn control mechanically the output of this tool.

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 PRESSURE RELIEF VALVE
Most hydraulic systems are designed to operate within a preset pressure range. This range is a function of the
forces the actuators in the system must generate to do the required work.
Without controlling or limiting these forces, the hydraulic components (and
expensive equipment) could be damaged. Relief valves prevent this
hazard. They are the safeguards that limit maximum pressure in a system
by diverting excess fluid when pressures become too high.

The pressure relief valve (PRV) is a type of valve used to control or limit
the pressure in a system or which can build up for a process upset,
instrument or equipment failure, or fire. The pressure is relieved by
allowing the pressurized fluid to flow from an auxiliary passage out of the
system.

Pressure relief valves are the quite common valves used in hydraulic
industries for performing two important functions as mentioned here.

 Protection against overload for

various circuit components
 Limiting the force or torque applied by actuators.

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Poppet will be positioned to its seat due to the spring force, one adjusting screw is provided to change the
setting pressure of relief valve.

If pressure at the inlet of relief valve is not enough to overcome the spring force, in that situation poppet will be
remain seated over its seat and will not allow the flow of fluid through it and therefore relief valve will be
closed and will not allow flow through it.

When pressure at the inlet of relief valve increases and overcomes

the spring force which was adjusted with the help of pressure
adjusting screw displayed at the top of relief valve, in that situation
poppet will leave the seat and will permit the flow of fluid through
relief valve.

Hence, if pressure at inlet of relief valve overcomes the setting

pressure of relief valve then fluid will flow to hydraulic reservoir
through relief valve and therefore further increment in pressure line
will be avoided.

For applications requiring valves that must relieve large flows with small pressure
differential, pilot-operated relief valves are often used

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Cracking pressure in relief valve operation is defined as the pressure at which relief valve first permit the flow
through it. Pressure at which relief valve allows to flow the full rated capacity will be termed as valve full flow
pressure.

Pilot Operated Pressure Valve

Pressure relief valve will have two sections i.e. Body section and pilot valve section. Body section of
relief valve will have a piston which will be retained to its position or seat due to the action of spring
force. Pilot valve section will control the piston movement with the help of hydraulic force.

Pilot relief valve is smaller than direct acting valves and have a wider range of maximum
pressure ratings. They can also be operated remotely using vent port (direct acting).

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 Pilot operated pressure relief valve will have
one small poppet type of relief valve and one
main relief valve as displayed in following
figure here. Pilot operated pressure relief
valve will have two ports like in simple type of
pressure relief valve. One port will be
connected with pump pressure line and other
port will be connected with hydraulic
reservoir.

The pilot-operated relief valve operates in two

stages. A pilot stage, which consists of a small, spring-biased relief valve (generally built into the main relief
valve), acts as a trigger to control the main relief valve. However, the pilot may also be located remotely and
connect to the main valve with pipe or tubing.

The main relief valve is normally closed when the pressure of the inlet is below the setting of the main valve
spring. Orifice B in the main valve, Figure 3, permits system pressure fluid to act on a larger area on the spring
side of the poppet, so the sum of this force and that of the main spring keep the poppet seated. At this time,
the pilot valve is also closed. Pressure in passage B is the same as system pressure and is less than the
setting of the pilot valve spring.

As system pressure rises, the pressure in passage B rises as well, and, when it reaches the setting of the pilot
valve, the pilot valve opens. Fluid is released behind the main valve through passage B to the drain port. The
resulting pressure drop across orifice A in the main relief valve opens it, and excess fluid flows to tank,
preventing any further rise in inlet pressure. The valves close again when inlet oil pressure drops below the
valve setting.

Pilot-operated relief valves typically have relatively low internal leakage until pressure reaches 80 to 90% of the
pressure setting, at which point the pilot stage may begin to open. These valves are best suited for high
pressure, high volume systems. Although their operation is slower than that of direct-acting relief valves, pilot-
operated relief valves maintain more stable pressure while relieving. Figure 4 plots the operating
characteristics of direct-acting and pilot-operated relief valves.

When pressure at inlet port of relief valve increases, then pressure in the secondary passage will also increase
and if pressure at inlet port of valve exceeds the setting pressure of relief valve then pressure force in the
secondary passage will overcome the spring force and hence poppet will leave its seat.

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Small amount of fluid flow starts to flow through the pilot line to the reservoir and it will create a pressure
difference across the piston and therefore piston as well as steam will leave their seats by moving upward due
to the pressure difference across the piston.

Once piston as well as steam leaves their seats, pilot operated pressure relief valve will be in open condition
and fluid will flow from pressure line to reservoir directly.

For similar pressure setting and flow, pilot operated pressure relief valves will be normally in smaller size as
compared to the direct acting pressure relief valves. Pilot operated pressure relief valve could be operated by
remote.

Note: Pilot operated pressure relief valve is also known as compound pressure relief valve and also known as
direct acting pressure relief valve.

Pressure-reducing valves

The most practical components for maintaining secondary, lower pressure in a hydraulic system are pressure-
reducing valves. Pressure-reducing valves are normally open 2-way valves that close when subjected to
sufficient downstream pressure. (Three-way valves are also available.) There are two types: direct-acting and
pilot-operated.

Direct acting — A pressure-reducing valve limits the maximum pressure available in a secondary circuit
regardless of pressure changes in the main circuit and as long as the work load generates no back flow into
the reducing valve port. When back flow does occur, the valve will close. The pressure-sensing signal comes
from the downstream side (secondary circuit). This valve operates in reverse fashion from a relief valve (which
senses pressure from the inlet and is normally closed). As pressure rises in the secondary circuit, Figure 5,
hydraulic force acts on area A of the valve,
closing it partly. Spring force opposes the
hydraulic force, so that only enough oil flows
past the valve to supply the secondary circuit at
the desired pressure. The spring setting is
adjustable.

Fixed-pressure reducing valves supply a fixed

amount of pressure reduction regardless of the
pressure in the main circuit. For instance,
assume a valve is set to reduce pressure by
250 psi. If main system pressure is 2750 psi, reduced pressure will be 2500 psi.
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Pressure and Flow Characteristics for a 4/3 Control Valve

Reference the 4/3 directional schematic above, note the flow areas from Ps to PA and PB to Pr are
equal (matched and symmetrical valve). Ignoring leakage through the servo piston, the flow rates
are characterized by the orifice flow equations,

(1)

(2)

The flow areas A1 and A2 are functions of valve position, xv. The load pressure drop and load flow
are given by

(3)

(4)

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Since Q1 = Q2, equations (1) and (2) can be combined, such that

(5)

Since return pressure is small compared to system pressure, we can let Pr = 0, leading to equation
(6)

(6)

Equations (3) and (6) can be combined to obtain

(7)

(8)

Equations (7) and (8) relate PA and PB to supply pressure and load pressure. If the load pressure is
zero, PA and PB are equal to ½ of the supply pressure.

For the load flow rate, equations (7) and (8) along with equations (1) and (2) can be substituted
into equation (4) to yield an equation for load flow in terms of supply pressure and load pressure.
The final equation is

(9)

This equation assumes Pr is negligible. Also, note that A1 = A2.

The above relationships for PL and QL are important for understanding theoretical pressure flow
characteristics of a four way, three position valve where the servo can be positioned in any position
along the bushing (infinitely variable flow area). These equations are used is the discussion of
hydraulic servo valves.

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