ANALYSIS AND SYNTHESIS OF THE DRIVE HYDRAULIC SYSTEM FOR THE DEEP INJECTION MACHINE M.Sc. Nikola Stanchev, Ph.D student TECHNICAL UNIVERSITY OF SOFIA Department of Hydroaerodynamics and Hydraulic Machines
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ANALYSIS AND SYNTHESIS OF THE DRIVE HYDRAULIC SYSTEM FOR
THE DEEP INJECTION MACHINE
M.Sc. Nikola Stanchev, Ph.D student
TECHNICAL UNIVERSITY OF SOFIADepartment of Hydroaerodynamics and Hydraulic Machines
GENERALLY REPRESENT, TECHNICAL DATA
An analysis and synthesis of consideration hydraulic system is based on a specialized unit to keep pressure in earth layers developed by the company "Gidronas" AD as an alternative to manufactured piston, centrifugal and screw pumps, used for such purposes, namely:
- Use one or more modules in parallel to transfer layer liquid or oil to the settling tanks or storage;
- To maintain the pressure in the layers through reinjection into the oil- bearing layer of liquid waste;
Specifications:
Capacity: 40-110, m³ / 24h;Rated output pressure: 10 to 15, MPa;Nominal inlet pressure: 0,4, MPa;Efficiency: 70%;
DESCRIPTION OF EXISTING SOLUTION
M
15 kW1450 rpm
C
P
SF
CV
PRV
28 cc
200 bar
M
15 kW1450 rpm
C
P
SF
CV
28 cc
B
H2O
pi
q ≈ 40 l/minq ≈ 40 l/min
A2M1 M2
WCV1
WCV2
WCV3
WCV4
PS1
q ≈ 160 l/minpmax = 4 bar
A1
PF
L
a5 a6 a7 a8
a1 a2 a3 a4
M
WP
CO
CGS2S1
VA1 VA4
VA2 VA3
Operating unit
Drive unit
ANALISYS OF EXISTING SOLUTION
Under the work condition of the existing system and technical analysis of the decision were identified the following problems and shortcomings:
- the function of combination of four valve groups, presence of hydraulic shocks
in the system due to parallel work of the separate valves;
- well configured system does not allow for quick and accurate failure detection and location of faulty element occurrence
This reflects on usability and on the allowable lifetime of the machine.
?
SYNTHESYS OF NEW HYDRAULIC SYSYEM
200 bar
M
15 kW1450 rpm
C
P
SF
CV
PRV
M1
28 cc
200 bar
M
15 kW1450 rpm
C
P
SF
CV
28 cc
PRV
M2
B
pi
q ≈ 40 l/minq ≈ 40 l/min
A2M3 M4
WCV1
WCV2
WCV3
WCV4
PS1
q ≈ 160 l/minpmax = 4 bar
A1
PCV1 PCV2
Pilot ratio1:3,5
Pilot ratio1:3,5
pi i
pPS2 PS3
P T
A B
a1 b1DV WP
PF
L
H2O
M
CO
CG
S1 S1
ADVANTAGES OF THE NEW HYDRAULIC SYSYEM
200 bar
M
15 kW1450 rpm
C
P
SF
CV
PRV
M1
28 cc
200 bar
M
15 kW1450 rpm
C
P
SF
CV
28 cc
PRV
M2
B
pi
q ≈ 40 l/minq ≈ 40 l/min
A2M3 M4
WCV1
WCV2
WCV3
WCV4
PS1
q ≈ 160 l/minpmax = 4 bar
A1
PCV1 PCV2
Pilot ratio1:3,5
Pilot ratio1:3,5
pi i
pPS2 PS3
P T
A B
a1 b1DV WP
PF
L
H2O
M
CO
CG
S1 S1
2 PRV+ 2 CV =
[p]
Only one directional element, simplifying of the system, alsoo ↓ the risk of damages
PCV = ↑q > ↓T for filling and empting of the accumulators >
increased productivity
Damping
NEED OF DEFECTATION FOR WORKING CIRCUIT OF THE SYSTEM
Defectation is necessary by the fact that the work fluid in the work unit is water with strong presence of contaminations, which influence of the correctly functioning of the system
For this reason is proposed methodic for correct defectation of the main components from the work unit - the valve devices WCV. The main damage occurred on hermetic sealed surfaces of the valve and on the leading (guiding) surfaces, which violates their proper function.
SOLUTIONS FOR DEFECTATION - WORKING CIRCUIT OF THE SYSTEM
p, bar
t, s0
180 ►
▲a1
PS1
▲b1
4 ►
p, bar
t, s0
180 ►
▲a1
▲b1
4 ►
▲a1
p, theoretical
p, actual
▲a1
PS1
Solenoid:
Solenoid:
Pressure characteristics, normal operation
SOLUTIONS FOR DEFECTATION - WORKING CIRCUIT OF THE SYSTEM
p, bar
t, s0
180 ►
▲a1
PS3
▲b1
4 ►
p, bar
t, s0
180 ►
▲a1
PS1
▲b1
4 ►
▲a1
p, theoretical
p, actual
▲b1
▲a1
▲b1
Non hermetic WCV2 Non hermetic WCV1
Non hermetic WCV3 Non hermetic WCV3, 4
Solenoid:
Solenoid:
Pressure characteristics, damage!
Functionality of the system is achieved in order to best match the existing requirements, significantly simplifying the structural performance;
Relative relieved failure analysis with defining the damage occurred, both in quality and in size;
Timely and accurate identification of defective hydraulic devices, without need for dismantling the system;
According to the pressure characteristics is possible to determine when and how to carry out repairs or replacement of the devices works;
All shown above reduces multiple the cost of failure analysis and timing of repairs.
CONCLUSIONS
THANK YOU FOR ATTENTION!
TU - Sofia, Department: HAD and HM
TU - Sofia, Department: HAD and HM
ANY QUESTIONS!?
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