Principle & manner of functioning

These figures specifies about hydraulic transmission

Exp = expansion tank

 =pressure pipe

=return pipe

= motor

When the pump is running the oil will flow through a pipe to the hydraulic motor. This will rotate by means of the
pressure from the pump. From the motor oil will lead back to the pump through the return pipe. A fixed oil
quantity is circulated in a closed system . An expansion tank is connected to the suction side of the pump to
compensate the volume variation of the oil. If a simple control valve is placed in between the 2 pipes some oil
can be led back to the pump without passing through the motor. In this way motor speed can be varied
steplessly from 0 to max & back.
 If the simple control valve is replaced by a 4-way valve, the hydraulic motor can be run in both direction the oil filter is
connected on the return pipe as close to the pump possible. Hydraulic pump needs a prime mover. The oil
fromthe pump flows through Pressure pipe to the control valve on the motor

Systems and components

Pump and motor systems are used for powering deck machinery such as
winches and windlasses. Pump and actuating cylinders are normally employed
lor hatch covers. One or more pumps will be used to supply the volume of fluid
at the pressure required to operate one or more motors. Pumps may be
classified into two groups:
1 those with a fixed delivery when running at a given speed;
2 those with a variable delivery at a given speed.
fixed delivery pumps can have their constant output bypassed via control
valves until required or output can be matched to requirements. by
incorporating a relief/accumulator. then stopping and starting, varying speed,
of connecting a variable delivery pump in parallel.
Variable delivery pump output can be controlled to give full flow in either
direction, and volume output can be varied from maximum down to zero.

fixed delivery pumps

constant output pumps of the gear or lobe type (see Chapter 5) are precision
made to provide high pressure with minimum back leakage. The former
operate on the principle that as gears revolve, fluid is carried around the outside
between the gear teeth and the housing from the suction to the discharge side
of the pump. Fluid from the discharge side is prevented from returning to the
intake side by the close meshing of the two gears and the small clearances
between the gears and housing. At the discharge side the fluid is discharged
partly by centrifugal effect and partly by being forced from between the teeth
as they mesh.
Gear pumps may be of the conventional kind or of the type with meshing
internal and external gears. Lobe pumps (Figure 5.28, p.173) are a variation of
the latter.
Axial cylinder pumps can be made to deliver a fixed output by setting the
swash plate for continuous full stroke operation.
Variable delivery pumps
Variable delivery pumps are used in hydraulic installations as the means of
regulating pump output to scit demand. Steering gears are controlled directly
by varying the pump output and swash plate pumps are used to supply a range
of hydraulic deck machinery. Automatic stroke control can be used to adjust
the output.
Constant delivery pump systems
Hydraulic steering gears which arc fitted with constant volume or fixed output
pumps may have a simple control valve arrangement which either delivers full
pump output to the steering gear or bypasses pump output completely.
System pressure rises sharply when oil is channelled to the gear. The fixed
output pumps of Woodward type hydraulic engine governors, supply to
accumulators, which maintain system pressure and hold a reserve of
operational oil against demand which may temporarily exceed pump capacity.
For general hydraulic systems where the pump delivers a constant volume
of oil. speed control of the hydraulic motor can be obtained by delivering the
required amount of oil to the motor through a control valve and diverting the
remainder through a bypass to the pump suction. The pump discharge pressure
is determined by the load. Speed and direction of rotation are controlled by a
lever operated balanced spool valve.
.
Unit type of circuit
The basic components of a hydrauliC system of the Norwinch design arc shown
in Figure 13..3.The pump in this case is of the vane type which consists of a
slightly elliptical case with a cylindrical rotor. The latter has radial slots
containing closely fitting rectangular vanes which are forced out against the
casing by centrifugal effect and oil pressure. As the rotor turns, the expanding
and contracting clearance between it and the casing produces a pumping
action. Both mechanical and magl)etic filters and a relief valve are provided.
The expansion tank contain a reserve of oil. The hydraulic motor is also vane type with the vanes mounted in a cylindrical
rotor working in a housing which incorporates two pressure chambers. When the motor is required to

Exert maximum torque, oil flow from the pump is directed into both chambers.
for lighter loads an operating lever is actuated to direct the full Bow to only one of the pressure chambers. This system provides two variable speed
ranges.
The system shown is for mooring winches which are self-tensioning.
Pumps for hydraulic installations, such as the one described, run at constant
speed and are driven by an electric motor or directly by a prime mover. With
t I••.pump running there is a continuous flow of oil through the system whether

II.•.motor is in operation or not. When the winch is not in use the oil merely
I··l~sesthrough the operating valve, bypassing the hydromotor and returns to
II.•. pump.
Oil pressure is negligible when the hydromotor is idle, reducing power
""juired to a minimum. Oil in the pipelines to and from the motor always flows
IIIthe same direction. At the motor controls the flow direction can be reversed
10 change the rotation of the winch.
Many of the hydraulic systems, fitted to deck machinery are of the 'unit'
Iypt', with one pump driving one motor, but there are great advantages to be
",lined by the use of a ring main system. With the latter type of system, one
•f'lIlrally located hydraulic pump is able to cater for the needs of a number of
.!lIdiaries which can work simultaneously or alternately at varying loads. As
IhI" equipment powered from this central pumping installation need not be
I •• ~Iricted to deck machinery or to one type of equipment, the system offers

mnsiderable savings on capital cost.

Vuriable displacement pump systems
he hydraulically operated steering gear wit~ an axial piston (vsg type) ot
radial piston (Hele-Shaw type) variable delivery pump, is an example of
varIable displacement pump system. The pump itself controls the liquid flow to
move a ram or vane steering gear, so that operational control valves are not
required. The variable delivery pump is driven at cons~ant speed by an a.c.
induction motor; the pump and motor being referred to in the regulations as a
power unit. The rate of oil flow from the power unit controls the speed of
movement of the steering gear and rudder. A small movement of the telemotor
linkage puts the pump on part stroke and the gear moves through a small
distance, slowly. When a large movement of the rudder is required, the
telemotor linkage puts the pump on full stroke and initially the gear moves
rapidly to take the rudder to the desired angle. As the rudder moves, the
hunting gear gradually brings the pump control towards neutral. lessening the
pump stroke, so that the rate of movement reduces.
A variable displacement system can be used for deck machinery such as
windlasses, winches and capstans and also for cargo pumps. The power unit for
such Circuitmay be an axial piston (vsg type) pump with swash plate control to
maintain constant pressure in the system. To match the demand of the
hydraulic motors being supplied the swash plate control servo-motor monitors
system pressure and automatically adjusts pump output to keep pressure
constant. Oil cooling is provided by conventional sea-water circulated, tube
type heat exchangers.
System design
Careful system design and contamination control are required during
manufacture and installation of equipment. The number of joints and pipes are
kept to a minimum to reduce the possibility of leakage. Materials are seleded
that will produce the least quantity of contaminating particles in the system.
Filters capable of taking out particles down to a 'Specified size are necessary.
Shaft glands or seals must prevent leakage of oil from the machinery and they
must also keep contamination out whether the plant is running or shut down.
It is important with all hydraulic systems to ensure that interlocking
arrangements provided for pump or motor control levers are in the neutral
position before the pump driving motor can be started, in order to avoid
inadvertent running of unmanned machinery. Overload protedion on
hydraulic systems is provided by use of the pressure relief valves set between
30-50% in excess of rated full load pressures.
With the lever in stop position, the oil passes only through the control Valve & back to the pump only through the
return pipe via oil filter.
The slide is operated by a control lever. With control lever is in stop pos & in case of the load is hanging on the hook,
the winch will try to move the motor in lower direction but will be prevented by pressure built up between the
vane of the hydraulic motor and the non return valve .If the slide is moved to upper side to the “hoist” position it
closes the bypass of the oil. The oil must therefore pass through the non return valve, which opens when the oil
pressure exceeds the torque of the motor. The motor will rotate in hoist direction. From the discharge
side of the motor, oil return to pump through control valve. If the slide is gradually moved down wards when
the load is hanging on the wire the oil will gradually escape from the pressure room in the motor & load will be
lowered, if the winch isn’t loaded & the slide is lowered to the “lower” position, the oil will be forced through the
motor in the opposite direction & the motor will lower.
As the motor will act like a brake by means of the pressure between the vanes & non return valve, its
not be necessary to have a brake except for emergency use.
- (a) the maximum speed of the motor is determined by the size of the pump. (Single speed motor).
- (b) The torque of hydraulic motor does not depend on the size of the pump.
The torque is determined by the size of the motor & work pressure.

Expansion tank is connected to suction side of hydraulic pump through a stop valve. When the pump is running the
valve should always open. For refilling oil a filling tank is connected to the expansion tank by a filling pump
&stop valve. An over flow pipe should be on expansion tank equipped with a sight glass & stop valve, which is to
be closed after filling. Care should be taken not to fill expansion tank above 2/3 of height.
The purpose of expansion tank is to compensate the variation of oil volume with respect to various losses, cater the
thermal expansion, to ensure a proper feeding at the suction side of the pump. Positioning of the pump should be
such that it should be vertically above the pump. The horizontal distance should be as minimum as possible .the
capacity of the tank should be approximately 6-8% of the total volume.

The piping system should be such that  it should have a continuous accent towards the expansion tank. When
several pumps are fed by the same tank the pipe junction to be arranged in such a way that the distance to each
pump should be approximately same.
Reinforced rubber hose used to avoid the vibration & is to be placed between the pump & the first pipe
clamp.
As these pipelines used for high pressure functions, hence they are with certain characteristics
1 ---- The welding grooves should be round.
2 ---- Bends & the pipe lengths are to be spot welded together between the flanges. Then dismantle the section & finish
welding. Remount the pipe & spot weld the flanges. Then dismantle and finish the welding of the flanges.
3 ---- flanges & joints are to be ground & brushed with a rotating sling of steel chain. If such sling is not accessible then
all welds to be hammered.
4---- the pipe section to be pressure tested.
5 ---- the pipe section to be put in an acid bath for some hrs. Recommended type acid is 97N or similar.
6--- the pipe section should be pickled. Recommended type pickle is Magnus26n or similar.
7 --- rinsed with water & dried with air
8 ---- inside of pipe should be sprayed with compressed air & spraying medium. Recommended is Magnafilm3160L.

Hydraulic systems

Hydraulic systems provide a means of distributing power and of obtaining it

from a constant speed and constant direction drive such as an a.c. electric
motor. The oil pressure can be used to provide variable speed drives through
hydraulic motors and power for actuating devices. Hydraulic power is used
extensively for deck machinery and remote control of valves.

Hydraulic systems
The three essential components for a hydraulic circuit, are the hydrauliC fluid
held in a reservoir tank. a pump to force the liquid through the system and a
motor or cylinder actuator to convert the energy of the moving liquid into a
working rotary or linear mechanical force. Valves to control liquid flow and
pressure are required by some systems.
 hydraulic oil
Hydraulic fluid
Water was the original hydraulic fluid and is still used for heavy duty such as
operation of lock gates or moving bridges. The disadvantages with water are
that it promotes rusting and other forms of corrosion, it is not a good lubricant
and it has a limited temperature range.
Hydraulic oils may be straight mineral or special additive oils. Properties of
these, enhanced by additives, include oxidation stability, film strength, rust
prevention, foam resistance, demulsibility and anti-wear characteristics to
enable the fluid to stand up to the higher operating temperatures and pressures
of modem systems. Pour point depressants are used to prevent freezing in low
temperature conditions. Other fluids used in hydraulic systems may be
synthetics or emulsions. Emulsions have been used in systems such as the
telemotor, where force is applied and received by pistons. Oils are preferred for
systems using rotating pumps and motors. where good lubrication is essential.
In an emergency where short term expediency is the criterion, any thin oU
could be used in a sysrem.

The oil is one of the main components of a hydraulic system & hence must be correctly chosen. Requirements
are such that
 1. viscosity index should be above 100.
 2. The oil must be of high shearing stability.
3. The oil must have additives to prevent wear , corrosion , & foaming.
 4. The oil must be of long life & have high thermal stability , humidity.
5. The oil must have low solubility in air & have ability to release air readily.
6. Must have good lubricating quality.
The viscosity of oil is closely related to the efficiency of installed machine .a thin oil reduce the efficiency at
high temperatures. Also a thick oil have starting difficulty at lower temperature .

Deterioration of hydraulic oils

Hydraulic fluids which are basically mineral oils, will degenerate very slowly
over time due to oxidation. The factors which encourage oxidation are the
heating and agitation of the oil in the presence of air and metal, particularly
copper. The process of oxidation is accelerated by overheati!lg and also by
contamination with products of corrosion or the presence of metal wear
particles. Oxidation products. both soluble and insoluble, ino;ease the oil's
viscosity and cause sludge to be deposited. Oxidation tends to encourage the
formation of emulsions with any water from leakage or condensation. Acidic
products of oxidation will cause corrosion in the system.

Contamination of oils
Water promotes rusting of steel and must be excluded from hydraulic systems.
Rust can be detached and when carried around a circuit can cause the jamming'
of those valves with fine operating clearance, as well as hastening deterioration
of the oil. Sea water can enter through the shaft seals of deck machinery and via
system coolers. Condensation on the cold surfaces of reservoir tanks which are
open to the atmosphere. is a common source of contamination by water. Tanks
should not be constructed such that cold hull plating forms one wall.
Metal wear is inevitable and fine filters are installed to remove these and
corrosion particles together with any other grit or dirt that finds its way into
the system. Care is necessary with hoses, funnels and oil containers used for
filling and topping up reservoir tanks, to ensure that they are clean.
Fine metal wear particles can act as abrasives causing further Wei!I. All
particles could cause blocking of small passages or the jamming of valves.

Electric drives
E1edric motors on vulnerable deck areas may be protected against ingress of
water by being totally enclosed in a watertight casing. Vents are provided on
some winches, which must be opened when the motor is operating in port.

The direct current (d.c.) motor, although it is relatively cosHy and require
regular brush gear maintenance, is still used for deck machinery because it has a
full speed range with good torque at any speed. The control of d.c. motors by
contactor-switched armature resistances, common in the days when ships’
electrical supplies were d.c., has long been replaced by a variety of
Ward-Leonard type systems which give a better, more positive regulation
particularly for controlled lowering of loads. The Ward-Leonard generator is
normally driven by an a.c. motor.

An important feature of the d.c. drive is its efficiency, particularly in

comparison with a.c. drives, when operating at speeds in the lower portion of
the working range. The d.c. motor is the only electric drive at present in
production which can be designed to operate in a stalled condition
continuously against its full rate torque and this feature is used for automatic
mooring winches of the 'live motor' type. The majority of d.c. winch motor
develop full oulput at speeds of the order of 500 rev Imin and where necessary are arranged to run up to two to four times this speed for light line
duties Windlass motors on the other hand do not normally operate with a run up in
excess of 2 : 1 and usually have a full load working speed of the order of
l000rev/min ..

Direct current motors may also be controlled by static thyristor controlled

which convert the a.c. supply into a variable d.c.voltage of the required
magnitude for any required armature speed. These converters must be of a type
capable of controlled rectification and inversion with bi-diredional current
flow if full control is to be obtained (Figure 13.1).

Alternating current induction motors, of either the wound rotor or of the

cage type are also in common use. With these the speed may be changed by
means of pole changing connections and in the case of the wound rotor
induction motor, also by changing the value of the outside resistance
connected in the rotor circuit. The pole change method involves the switching
of high currents at medium voltage in several lines simultaneously, requiring
the use of multi-pole contactors. The pole change speed control method offer.
a choice of perhaps three discrete speeds such as 0.65, 0.325 and 0.1025 m/s.
corresponding to 4, 8 and 24 pole operation. The wound rotor motor is flexible
when hoisting a load, because the starting resistances can be reintroduced into
the rotor circuit and the load will cause the motor to slip. The slip gives a range
between the speeds dictated by the pole arrangement. As with resistance
controlled d.c. motors, difficulty is experienced when providing speed control
of an overhauling load, i.e. lowering a suspended load. TIle disadvantages must
be balanced against lower cost. particularly of the cage type induction motor,.
in comparison with the more flexible d.c. motor.

The a.c. drives described operate at the supply frequency and consequently
rapid heating of the motor will occur if the drive is stalled when energized.
The majority of a.c. motors on deck machinery run at a maximum speed
corresponding to the 4 pole synchronous speed of 1800 rev Imin on a 60 Hz
supply. These speeds are similar to the maximum speeds used with d.c. drives and the bearings and shaft details tend to be much the same. The motor
hearings are normally grease lubricated. However, where the motor is flange
mounted on an oil bath gearcase, the driving end bearing is open to the
gearcase oil and grease lubrication is not required.