EFFECT OF FILTER UNIT BACK PRESSURE TO THE WATER...

EFFECT OF FILTER UNIT BACK PRESSURE TO THE WATER HYDRAULIC

SYSTEM PUMP PERFORMANCE

HOBEEKIM

A project report submitted in partial

Fulfillment of the requirements for the award of the

Degree of Bachelor Mechanical Engineering {Thermal Fluids)

Faculty of Mechanical Engineering

Universiti Teknikal Malaysia Melaka

: . JUNE 2012

© Universiti Teknikal Malaysia Melaka

"I hereby declared that I have read this thesis and in my opinion this thesis is

sufficient in terms of scope and qualify for the award of the Degree of Bachelor

Mechanical Engineering (Thermal Fluids)".

Signature

Name of Supervisor

Date

~_.:Q ... ~ .................... .

.. ~!.?.:J.'::: ... ~.~~ .... ~~-~-~-~-~:J..S I L I .;l.O I :2.-


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"I hereby declared that this is my own work except the ideas and summaries which I

have clarified their sources"

Signature

Author

Date

~0 &~~ ttM ....................................... ......................

......... !f{. .. !.J. ... ~.'-~······· · · · · ·· ··· · ·· ·


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Special dedicate to

My lovely

family, supervisor, friends, and all that help me to finish my thesis.


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IV

ACKNOWLEDGEMENT

Through this few months, many people have been helped in this project, and I

always being grateful for their valued suggestions and comments. Specially, I wish to

acknowledge the assistance of my supervisor, Encik Faizil Wasbari, when carry

through the whole project. A special note of thanks is given to my supervisor that

diligently checked all of the text and problems. Besides, I would like to express my

gratitude to Universiti Teknikal Malaysia Melaka (UTeM), for giving me this

opportunity to undergo Final Year Project.

Besides, I would also like to thank to my panels, Encik Safarudin Gaza1i

Herawan and Encik Mohamad Firdaus Sukri. Thanks to their guidance, advices,

critics and motivation during the presentation.

Besides, many thanks are extended to all of my friends and course mates who

are always willing taken the time to help me when I needed, especially Ali Ilman Bin

Abdullah Sudin, Zamir Bin Mustafa, Ahmad Syauqi Bin Ahmad Shukri, Dang Jia

Ming, Siti Khadijah Ab Yusop and Muhammad Zaidi. I am very appreciate of the

helps and guidance that been given all the time.

Last, but certainly not least, the continual encouragement and support of my

families and friends is deeply and sincerely appreciated.


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ABSTRACT

This thesis presents a study of the effect of back pressure of filter unit in the

water hydraulic system. The main purpose of this project is to study the difference of

performance of a water hydraulic system with filter and without filter unit

installation. The other purpose of the project is to study about the effects of flow rate

to the back pressure of filter unit in the water hydraulic system. An application

system which is an automatic operated door in water hydraulic system has designed

to test the performance of the system with the existence of back pressure. The

designed application system was simulated by using fluid simulation software to

simulate the motion of the system. The hydraulic circuit will then help in set up of

the experiment. Comparison experiment with filter and without filter was tested to

examine the effect of back pressure in the performance of water hydraulic system.

Another experiment will be carrying out to test the effects of different flow rate to

the back pressure in water hydraulic pump system. As a resul-t, the formation of back

pressure was detected with the installation of filter cartridge in the system. With the

increased of flow rate, the back pressure showed increment in the system. A few

recommendations were suggested to improve the performance of water hydraulic

pump system-.


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ABSTRAK

Tesis ini membentangkan kajian yang berkaitan tentang kesan tekanan balik

unit penapis di dalam sistem hidraulik berasaskan air. Tujuan utama projek ini adalah

untuk mengkaj i tentang perbezaan prestasi sistem air hidraulik dengan penapis dan

tanpa pemasangan unit penapis. Selain daripada itu, projek ini juga mengkaji tentang

kesan kadar afuan kepada tekanan balik unit penapis di dalam sistem air bidraulik.

Aplikasi yang merupakan pintu automatik yang dikendalikan dalam sistem hidraulik

berasaskan· air telah direka untuk mengk:aji prestasi -sistem dengan kewtijudan

tekanan balik. Sistem apikasi yang direka telah disimulasi dengan menggunakan

perisian simu:lasi bendalir tmtuk mensimulasi:kan pergerakan sistem. Litar hidrattlik

akan membantu dalam ujikaji. Ujikaji perbandingan dengan penapis dan tanpa

penapis akan diuji untuk mengkaji kesan tekanan balik dalam prestasi sistem air

hidraulik. Satu lagi kajian akan dijalankan untuk menguji kesan kadar aliran yang

berbeza kepada tekanan balik dalam sistem pam hidrauiik air. Hasilnya,

pembentukan tekanan balik dikesan dengan pemasangan unit kartrij penapis dalam

sistem. Dengan petringkatan kadar aliran, tekanan balik menunjukkan peningkatan

dalam sistem. Beberapa penambahbaikan telah dicadangkan untuk memperbaikikan

prestasi sistem hidraulik berasaskan air.


CHAPTER

TABLE OF CONTENTS

TITLE

DECLARATION

DEDICATION

ACKNOWLEDGEMENT

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PAGE

i

iii

iv

CHAPTER 1 INTRODUCTION .......................................................................... !

1.1 Overview .................................................................................. 1

1.2 Objectives ..... ..................... ........... ..... ....................................... 2

1.3 Seopes .................... .................................... ........................... ... 2

1.4 Problem Statements ................................................................. 2

CHAPTER 2 LITE-RA TU'RE RE'VmW •••.••••.•.•...••.•.••••.•.•..•.•...•..•.••...••.•.•..•.•••..• 3

2.1 Introduction ............................................................. ..... ..... ...... 3

2.2 Definition of Back Pressure .... ..... ...... ............... ..... .................. 3

2.3 Water Hydraulic System and Components .. ................ ........... .4

2. 4 T-ypes of Contamination .............. ........... .... ..... ...................... ... 6

2.5 Causes of Contamination ............................................... .. ........ 7

2.6 Problems Caused By Contamination .............. ..... ..................... 7

2. 7 Types of Filter ............................. .......... ..... .... ....... .......... ......... 8

2.8 C-lassification of Filter ........ ..... ................ .......... ................ ....... 8

2.9 Locations of Filter ........................ ...... ...................................... 9

2.9.1 Inlet Line Filter ........ ............................... ................. 11

2.9 .2 Pressure Line Filter .................. ...................... .......... 11


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2.9.3 Return .Line Filter .. ................................................... 11

2.10 Formula and Calculation .. ....... .................... ......................... 12

2.11 Application of Water Hydraulic System .............................. 15

2.12 Contributors of Back Pressure in HPLC System ................... 16

2.13 The Effects -of Back Pressure of Fi-lter ................................. 1 7

2.14 Impact of Membranes Filter on Filtration System

Performance- ....................................................... ................ .... 18

2.15 Impact of Plugged and Clogged of Filter in Filtration System

Performance ...... ..................................................................... 20

2.16 Impact of Flow Rate to the Back Pressure Filtration System ...

.............................................................................................. 21

CHAPTER 3 METHODOLOGY ........................................................................ 23

3.1 Introduction .................................................................. .......... 23

3.2 Flow Chart of Methodology .... ............................................... 24

3.3 Development of Water Hydraulic· Pump System ................... 26

3.3.1 Design & Fabrication of the Application System ..... 26

3.3.2 Power Supply Unit .................................................... 28

(a) Reservoir ......................................................................... 28

(b-} Electric Motor ................................................................. 29

(c) Water Pump ............. ........................................................ 31

(dt Filter ..................... ........... .......................................... ...... 32

3.4 Control System ....................................................................... 33

3.4.1 Hydraulic Control System ................. ....................... 33

3.4.2 Electrical Control System ......................... ................ 38

3.5 Actuator ................. .... ..... ..................................... ..... ........... ... 4J

CHAPTER 4 DEVELOPMENT OF HYDRAULIC & ELECTRO CIRCUIT

SI"MU'LA TIO N .............................................•............................. 44

4.1 Application of Water Hydraulic System ............ .................... 44


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4.2 Appl-ication of Water Hydraulic System in Automatic Operat.Qr

Door ...... ..... ............................................... .......... .................... 46

4.3 Physical Layout of Automatic Door Assembly ...... ..... ........... 48

4.4 Working Mechanism of Automatic Door. ......... ...... .............. .49

4.5 Hydraulic & Electro Circuit Simulation of the Design

Application System ................................................................ 49

CHAPTER 5 EXPERIMENTAL DATA & RESULT ...................................... 52

5.1 Breakaway Time .......... ................. ..... ..... .............................. 52

5.2 Cylinder Speed ............................................................ .... ...... . 53

5.3 Pressure Comparison With & Without Filter ............. ........... . 54

5A Back Pressure Pro-file· with Different Flow Rate .................... 56-

CHAPTER 6 ANALYSIS & DISCUSSION ...................................................... 58

6.1 Breakaway Time .................................... ............... ................ 58

6.2 Cylinder Speed ....................................................... ................ 59

63 Pressure-comparison Without and With Filter ...................... 61

6.4 Back Pressure Profile with Different Flow Rates .................. 64

CHAPTER 7 CONCLUSION & RECOMMENDATION ............................... ,8

7.1 Conclusion ...................................................................... ........ 68

7.2 Recommendation ....... ..... ..... ..................... .......... ..... ........... .... -69

REFERENCES

APPENDICES


71

73

X

LIST OF FIGURES

NO TITLE PA-GE

2.1: Schematic Diagram of Water 4

2.2: (a) FuU Dow filter (b) Proportional Dow filter 8

2.3-:- Inlet Line Filter 9

2.4: Pressure line filter 10

2.5! Return Hne filter- lO

2.6: Pascal's principle 12

2. 7: Continuity of Dow 14

2.8: Change in system backpressure depends on filtration membrane used to

prepare UHPL£ mobile phase· ·19

2.9: Orifice plate Dow meter 21

3.1-: Flow chart of methodology 24

3.2: Detail drawing of the automatic door 26

3.3: MOOel-of the automatic -door 27

3.4: Reservoir 28

3.5: Connector 2-9-

3.6: Electric motor 29

3. 7: Power transmission-system 39·

3.8: Water pump 31

3.9: Stainless steel filter 32

3.10: Nylon cartridge 32

3.11: Pressu-re ·regulator 33·

3.12: Pressure gauge 33

3.13! Ball valve 34

3.14: 3/2 Way solenoid valve 35

3.1-5: Male~tud 36


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3.16: Male branch tee fitting 36

3.17: Construction of male branch tee fitting with pressure gauge 37

3.18: ln·let bose 37

3.19: PVC tube (6 mm) 38

3.2 .. PVC tube{lO mm) 38

3.21: DC power supply unit 38

3.22: Plug 39

3.23: Schematic diagram of plug 39

3.24: 4 poles relay 39

3.25: Relay base 39

3.26: Single pole relay 40

3.27: Contact port diagram 40

3.28: Timer 40

3.29: Schematic diagram of terminals 40

3.30: Limit switch 41

3.31: Photoelectric sensor 41

3·.32: Wires connector 42

3.33: Double acting cylinder 43

4.1: Standard sliding door 46

4.2: Curve sliding door 46

4.3: Telescopic ·sliding door 46

4.4: Angular sliding door 47

4.5:- Physical layout of automatic door assembly 48

4.6: Hydraulic & electro circuit simulation of the design application system 49

4.7: Modified hydraulic & electro circuit simulation -50

5.1: Setup of experiment for with & without filter cartridge 55

5.2: Setup of measurement of back pressure prof"de 57

6.1: Graph of breakaway time versus setting pressure 58

6.2: Cylinder Extending Speed-versus Pressure 59

6.3: Cylinder Retracting Speed versus Pressure 60

6.4~ Pressure without f"dter cartridge versus pump pressure 61

6.5: Inlet & outlet pressure with filter cartridge versus pump pressure 62

6.6: OveraH Comparison o-f Inlet & Outlet Pressure with & without Cartridge63

6.7: Back pressure versus flow rates 64


.6.8: Dlustration .()( iMreased ba~kpressure by flow rates

6.9: Back pressure without cartridge versus distance

6.10: 8Kk pressure-with -cartridge versus distance

6.11: Difference pressure versus pump pressure


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65

65

{;(;

67

LIST OFT ABLES

NO TITLE

2.1: Percent retention efficiency for filtration of 0.005 °/o latex -suspension

(0.3 Jlm) through 0.2 Jlm membrane filters)

3.1: Specifications of electric motor

3.2: Specification of water pump

3.3: Specification of filter

3.4: Specifications of ball valve

3.5: SpecifieatioDs of 3/2 -way ~olenoid

3.6: Photoelectric sensor

5.1: Breabw-ay time

5.2: Extend stroke time without filter

5.3: Ext-end stroke time -with filter

5.4: Retract stroke time without filter

5.5: Retract stroke time with filter

5.6: Cylinder extending spe-ed

5. 7: Cylinder retracting speed

5.8: Pressure· ·reading without filter cartridge

5.9: Pressure reading with filter cartridge

5.10: Measurement of flow rates


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PAGE

19

30

31

32

34

35

42

52

53

53

53

53

54

54

55

56

56

5.11: Ba~k pressure with dift'erent flow rates

6.1: Pressure comparison


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56

63

XV

LIST OF NOMENCLATURES

A Cross Sectional Area

D Diameter of cylinder

F Foree

N Angular Speed

p Pressure

Power Power that generated

Q Flow Rate

s Distance moved by piston

t Time

v Volume-

v Velocity

w Work


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LIST OF APPENDICES

NO TITLE PA-GE

1 Description of the simulation of hydraulic & electro circuits 73-78

2 Gantt Chart PSM 1 97

3 Gantt Chart PSM2 98


1

CHAPTER I

INTRODUCTION

1.1 Ov·erview

Water hydraulic system pump· is a system in which water is drawn from tank to a

system by using a pump. The pump is driven by a motor so that it can be turned. A

filter is added before water flow from the tank into the pump to avoid any

unnecessary dirt particles flowing in the system.

A water hydraulic system pump depends· on the pressure of water. The pressure

of water is best in interpreting the performance of water. However, the existing of

filter in the water hydraulic system may influence the pressure of water, especially

the back-pressure of the filter. Pressure gauge is installed in the system to measure

the difference of pressure change with and without the existence of filter. Besides,

the variation of pressure in the system also will be observed in the project by

manipulate the different pump flow rate.


1.2 Obje~twes

This project is about investigating the effect of filter unit back-pressure to

the water hydraulic system performance pump. The objectives are as follow:-

1. To fmd the pressure comparison between without fitter and ·with filter

unit.

n. To find back-pressure profile with different pump flow rate.

1.3 Scopes

The scopes of the project are-as follow:-

1. Setup a water hydraulic- system pump.

n. Run the pressure comparison experiment between without filter and with

fi1ter unit.

m. Collect data of back-pressure profile with different pump flow rate.

rv. Propose ·improvement of filter ·unit in the performance ·of water

hydraulic system pump in case of necessary.

1.4 Problem Statements

2

The advantages that bring by filter in the hydraulic- system are undeniable such- as

the ability to prevent dirt particles, reduce the frequencies in maintenance of the

pump system and so on prolong the life span of the whole hydraulic system.

However, the back-pressure that bring by filter has badly influenced the performance

of the pump system. The problems include generating of excessive case pressure,

seal failure and also the mechanical damage that bring to the system. Besides, the

high back pressure will lead to leakage of the pump suddenly which is then caused

injuries. More research and experiment are required to study the problem.


3

CHAPTER2

LITERATURE REVIEW

2.1 Introduction

In this section, the effect of the back -pressure of filter unit to the water

hydraulic system will be review through trustable journals and books which has

published. This part of discussion helps in more understanding -about the approach of

the project. It is a summary and synopsis of the study in the field of the project.

2.2 Def"mition of Back Pressure

"A condition ·in which the owners system pressure is greater than the

suppliers' system pressure." Environment Protection Agency (2003 ). "Cross

connection Control Manual." United States: (EPA 816-R-(H-002)-Baek pressure will

be generated when fluid is pump through an obstructions or tight bends by a

confinement vessel. The obstruction here is point to the filter unit while· the

confinement vessel is mean to be the water pump. Backflow is the undesirable

-reversal of :flow of non-portable water 6r other substances through a cross-connection

and into the piping of a water system. Back pressure is created when an undesirable

backflow exists in a water system. A good quality of filter may create higher back

pressure compared to a less quality of filter. A good quality of filter has finer

structure so higher back pressure wiH be created. As back pressure increases, the


4

water flow rate wiU become smal-ler. In case filter gets- clogged, then more force is

needed to pump water through the ftlter.

2.3 Water Hydraulie System and Cmnponents

Water hydraulic system is a system which uses water as a pressurized

medium in power transmission for machine apparatus, stuff handling devices,

transport and etc. Water hydraulic system helps in reducing fire hazards, operating

cost and contamination. It also contributes to the low volume applications and

environmental friendly.

R . _.J-.,_

eservorr -1' Pump

Filter ---J

-_,

Application

System

__ ,

Actuator

Figure 2.1: Schematic Diagram ofWater

Due to the patent (Roger, 1-971), Figure 2.-1 shown the basic components of

water hydraulic system are hydraulic fluids, reservoir, pump, filter, valve, actuator

and etc. The descriptions of these components are shown below:

1. Hydraulic fluids

Water acts as a working fluid in the water hydraulic system, it is non

compressible so that can transmit power easily from one end of the

system to the other end of the system. It is also use to lubricate the


5

moving parts. in the system to reduce friction loss and help to cool .the

components in the system. Besides, the working fluid should assist in

removing contaminant-s to filter to avoid blockage. It also plays role as

seal against leakage inside a hydraulic component of the system.

n. Reservoir

The function of a reservoir in water hydraulic system is used to store

the system's fluid which is water. Generally, the material of reservoirs

is stainless steel or plastic or metal which coated with metal corrosion

resistant material. The size of reservoir is larger than conventional

hydraulic system.

111. Pump

Pumps used to create flow in water hydraulic system. Fluid is drawn

into the cavity of pump opening during the half cycle and then- expels

the fluid from the cavity of the pump closing for the other cycle.

(Andrew, March 1999) Various types of pump can be used in water

pump system such as piston pump, gear pump, vane pump, axial

piston pump, radial pump and etc.

tv. Filter

This device use to keep clean for the system component from dirt and

minute particles. 'This can help to prevent blocking in the -components

of the system and avoid from wear of those components. Filter can be

installed between the components of the system and also install in the

reservoir. The coarse type of filter install in the reservoir to remove

large particle, while separate filter install between the components of

the system to remove finer elements from entering the system.

v. Valves

There are three types of control valves can be used in water hydraulics

system pump. Generally, the control valves inelude directional control

valve, pressure valve and flow control valves. The function of

directional control valves is ·used to ·control the water flow path by


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.changing the ports of the valve so that flow of fluid can be direct .to

the desire way. Pressure valves are divided into pressure relief valves,

pressure reducing valves and sequence valve. Pressure relief valves

are use to control the overloading of flow in the system. While

pressure ·reducing valves and sequence valves are used to reduce the

supply pressure and using pressure to manage the sequence of

hydraulic circuits.

v1. Actuators

Actuators that used in the hydraulic system are cylinder and hydraulic

motor. Cylinder which is also called as linear actuator is used to

produce straight line motion for the hydraulic system pump. There are

two types of cylinder which are single acting cylinder and double

acting cylinder. The single acting cylinder has only one fluid chamber

and produce force only in one direction. While the double acting

cylinder can operated in two ways and power stroke can be produced

in either way. Hydraulic motor also cal-led as rotary actuators which

can produce rotary motion for the hydraulic pump.

2.4 Types of CODtamiDation

Generally, contamination divided into two types, externally contamination

and internally contamination. External contaminant is generated from outside the

·system while internal contaminant is generated within the system. Both types -of the

contaminants are grouped as particulate contamination which is made of various

materials of solid particles. External contaminant includes dirt, grimes and others.

Internal contaminants exist when some of the components of the system wear. The

contaminants may come from wear pump;, actuator, seal and bearing. (Weibing D. &

Larry S., 2004)


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2.5 Causes of Contamination

According -ttt Majumdar S.R. (2002), contaminants can be generated in a

hydraulic system through:

• Insufficient cleaning of component parts which generated d-uring

manufacturing or assembly).

• The -refilt fluid-may be-polluted before entering the system.

• Wear particles are continually being generate by an operating system.

• Chemical breakdown of the hydrau-lic fl-uid.

• Occurring of cavitations.

-e- Ingest airborne contaminants throu-gh -air breather and -cylinder rod seals.

• Ingestion of contaminants during servicing or installation or replacement of

components in the system.

2.-6 P-roblems Caused- By Contamination

A number of problems which caused by contaminant are stated in Majumdar

S.R. (2002) as shown as below:

• S-peed- up the wear of components in the sys-tem, thu-s influ-ence the s-ystem

performance and service life.

• Slow dttWn the operat-ion of the system and cau-se the moving parts not

operate smoothly.

• Score finely finished s-u-rfaces and- lead- to-leakage by damage seal.

• Causing leakage and losing control during operation when contaminants stop

valves from sealing properly.

• Act as a catalyst in assisting the oxidation of hydraulic and breakdown.


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EFFECT OF FILTER UNIT BACK PRESSURE TO THE WATER...

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