Running head: WATER AS A PRESSURE MEDIUM

Faculty of Engineering
University of Kragujevac

Water as a Pressure Medium in Hydraulic Power Transmission Systems

Student: Professor:
Marta Ilić 440/2017 Dr Sandra Stefanović
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Table of Contents

Introduction ................................................................................................................................ 2

Water hydraulics ........................................................................................................................ 3

Historical development ...................................................................................................... 3

Comparison with other power transfer systems ................................................................. 4

Problems of water use in hydraulic systems and their solution ......................................... 5

Water properties and their effect in the hydraulic system ......................................................... 6

Density ............................................................................................................................... 6

Specific heat ....................................................................................................................... 8

Viscosity ............................................................................................................................ 8

Possibility of using water hydraulics ....................................................................................... 10

Food industry ................................................................................................................... 11

Mobile hydraulic systems ................................................................................................ 12

Conclusion ............................................................................................................................... 13

References ................................................................................................................................ 14
WATER AS A PRESSURE MEDIUM 2

Introduction

Hydraulics are now very much represented in the industry and there is almost no area
in which they are not used. Its application can be seen in the food industry, the pharmaceutical
and chemical industries, the nuclear industry as well as in mobile systems. By the beginning of
the 20th century, water was the only available fluid in hydraulics, and after that began to
develop systems using oil or other liquids, such as some synthetic fluids. However, the
problems that occur during the use of oil, such as pollution of the environment during its
discharge and flammability, have led to the recycling of water as a medium in hydraulic
systems.

The main advantage of the water is large flow through the pipes with relatively small
cross sections without major losses, which is due to the low viscosity of the water. The
advantage of using water is its availability, low usage price and the fact that water leaks easily
without leaking oil leaks. The most important of all is that it does not present a fire hazard and
does not pollute the environment. The main disadvantages of water, as working fluids, are the
risk of corrosion and the lack of sufficient lubrication between the moving parts of the machine,
as well as a limited range of operating temperatures. However, thanks to the advancement and
technology development, today, with the right choice of materials and design solutions, we can
very successfully eliminate deficiencies and get reliable, and, as far as price is concerned,
affordable systems.

Hydraulic systems with water as a medium or shorter hydraulic hydraulics do not differ
significantly from the oil hydraulics or hydraulic system using oil. Although its oil had
advantages over water whose use was initially limited by many problems, today is not such a
situation.

A series of new components that are exclusively developed for working with water have
led to the fact that today hydraulic hydraulics in their properties does not lag behind the oil. All
this indicates that the future of hydraulic hydraulics is very good and that the water can soon
return to the top of the use in hydraulic systems (Erik Trostmann, 1996).

.
WATER AS A PRESSURE MEDIUM 3

Water hydraulics

In this chapter will give a historical development of the use of water as a working
medium in hydraulic machines.

Historical development

Water has been used as a power transfer since ancient times. The first pump was created
in the second century BC. It was a two-volt pump, which was used for pumping water, and its
inventor was Cetibus from Alexandria.

Shortly after the invention of the first steam engine in the 18th century, due to its
precision and economy, the technique of using liquid (water) under the pressure for power
transmission has significantly increased. In 1795, Joseph Bramah was granted a patent for the
invention of the first hydraulic press. With the Industrial Revolution in Great Britain, in the
mid-19th century, the use of fluid power for presses, lifts, cranes, extrusion machines, etc.
began. In London and other cities, a central industrial hydraulic network (London Hydraulic
Power Company) was built. This network has sent thousands of power to its customers and is
still in use today.

At the beginning of the 20th century, the development of the electricity supply network
slowed down the progress of hydraulics. In 1905, the first hydraulic system with oil was used
as a working fluid. This replaced electromechanical systems with warships (for raising and
setting guns). Radial piston machines were introduced in 1910 by H.S. Hele-Shaw and in 1922
by Hans Thom. Later, pumps with variable volumes were found. The pre-loaded pressure relief
valve was controverted by Harry Vickers in 1930.However, only after the Second World War,
the use of hydraulics in power transfer and management has begun to really develop. New
hydraulic components systems are designed and implemented in many cases. An important
breakthrough was the development of electro-controlled distribution valves for automatic
machine control.

Some significant breakthroughs were observed in the 1950s when an axial piston pump
with a sloping plate and electrohydraulic servo valves for the servo devices was conserved. The
development and use of hydraulic power transmission systems, which use oil as a working
fluid, continued to this day. These systems are mostly used in hydraulics. In 1978, the Royal
Navy (UK), in cooperation with the National Engineering Laboratory (NEL), contracted the
development of submarine systems that use seawater as a working fluid for power transmission.
WATER AS A PRESSURE MEDIUM 4

Later, the Shell / Esso company contracted with NEL to continue the development of submarine
and marine-based systems. Danish company Danfoss was the first in the world to introduce in
1994 a brand new hydraulic hydraulic technology, Nessie, which uses pure water as a working
fluid, and has the same characteristics as hydraulic systems using oil.

By using water as a working fluid, two major oil hydraulic defects have been overcome:
pollution caused by leaking oil in the environment and the risk of fire and explosion of mineral
oil. At the same time, hydraulic hydraulics, using excellent construction solutions of bearings
in pumps and motors and the selection of special materials for the production of components,
overcame the basic shortcomings of the old water hydraulics: the problem of correct lubrication
of the moving parts of the components and the problem of corrosion protection (Erik
Trostmann, 1996).

Comparison with other power transfer systems

Unlike most electrical systems, water hydraulic systems are more suitable for
maintenance, as they can be adapted to all common cleaning methods, which is especially
useful in the food, chemical and petrochemical industries, while electrical systems require
special modifications. One of the many problems that occurs with electric motors is that they
need cooling. The food industry, for example, requires hygiene, waterproofing of system
components, as well as constant room temperature. As a result, engines are often found in
stainless steel cases, which must be dismantled, cleaned and ventilated, which increases service
costs. On the other hand, in systems using water, the heat generated in pumps, motors, valves
and pipes is transferred to a hydraulic fluid which can easily be removed from critical
temperature areas very easily and without high costs. It should be noted that electric motors are
often placed far from the wet processing zone, so gearing, chains, shafts are required for power
transmission, which requires lubrication and thus possible hygiene problems, as well as more
space and costs.

In comparison with electrical systems, hydraulic hydraulics have the following advantages:

 Very compact components;

 Minimum heat generation;
 The system is sanitary and easy to clean;
 The protective housing is not necessary and the system can operate directly in the wet
zone.
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In comparison with pneumatic systems, hydraulic hydraulics have significant

advantages in efficiency and regulation. The volume of water changes very little under
pressure, which gives good positioning characteristics; Low viscosity means low pressure drop,
while high pressure (140 bar) results in a compact component design. Pneumatic systems have
low efficiency, as well as hygienic and environmental problems. Pneumatic systems can miss
25% of their compressed air in the production area, with unstable movement and poor position,
and therefore require hiracular fluid stabilization cylinders. Their relatively low operating
pressure means that motors and cylinders often have to be substantially larger than the
corresponding hydraulic equipment. Tires tend to be inefficient, with possible power losses up
to 85-90% when compressors, air drying equipment, pipes, valves, motors and cylinders are
included. Danish slaughterhouses achieved energy savings of as much as 88%, replacing
pneumatic motors on rotary meat testers with hydraulic motors (Erik Trostmann, 2001).

Problems of water use in hydraulic systems and their solution

The problems that arise with the use of water in hydraulic systems are as follows:

1. Leakage–The water has a low viscosity, so the external and internal leakage control is
difficult. This problem is solved by using systems that are specially designed to work
with water and are made of corrosion-resistant materials. With the introduction of new
materials, such as ceramics and polymers, components are designed to reduce internal
leakage, reduced spacing and wear.
2. Erosion–Water has a lower viscosity and higher weight, which can lead to higher speeds
and turbulent flows. High speed and turbulence can corrode metal surfaces. Today's
hydraulic systems that are designed to work with low viscosity water successfully
prevent this problem. Special valves, materials and coatings combined with speed
control successfully combat erosion.
3. Corrosion–Oxygen and sulfur are by-products of bacteria, which can lead to the
corrosion of materials of certain components of the hydraulic system. Stainless
materials, such as stainless steel or specially treated aluminum, can prevent corrosion.
This can also be achieved by using glass fibers, ceramic materials, plastics and other
synthetic materials. Additives also contribute to the fight against corrosion by coating
surfaces that have the potential to corrode.
4. Temperature–The water temperature as a medium in the hydraulic system ranges from
2 ° C to about 50 ° C, depending on the components used. In case of water seepage, the
WATER AS A PRESSURE MEDIUM 6

system is heated at a minimum temperature. Antifreeze can also be used, but it is

important that its selection is good so as not to disturb other characteristics of the
working medium.
5. Hydraulic Impact–A hydraulic stroke occurs when the fluid abruptly stops, which is
usually caused by a quick closing of the valve. By properly designing the system and
selecting components, this phenomenon can almost be eliminated. Valves designed for
controlled closing and opening, can provide precise acceleration or deceleration of the
fluid. The use of the battery can reduce the rigidity of the system, and its size depends
on the operating pressure.
6. Lubrication–Low water lubrication can lead to increased contact friction and wear of
parts. Conventional components require lubrication. By using components that contain
coatings or are made of special materials, water acts as a lubricant. Additives can also
improve lubricating properties of water (Jaklin, 2012)1.

Water properties and their effect in the hydraulic system

This chapter defines and describes certain physical properties of water that are essential
for the operation of the hydraulic system. Also graphical and numerical relations will be shown
for both water and mineral oil. Basic water features are:

 Density;
 Specific heat;
 Viscosity;

Density

The density represents the mass per unit of volume, is denoted by ρ and is expressed in
[kg/m3]. This physical size depends on the temperature and the pressure and affects the
hydraulic energy losses in the system. It is therefore important that the working fluid density
be as low as possible, in order to reduce pressure losses and a dynamic effect on the control
valve. Figure 1 shows how water density affects temperature and pressure, while Figure 2
illustrates the comparison of the amount of mineral oil and water scrubbing. It is noted that the
variation in relative density as the pressure function is greater for mineral oil than for water
(Erik Trostmann, 2001).

1
Jaklin, I., (2012). Hydraulic systems. Zagreb: University of Zagreb, Faculty of Mechanical Engineering and
Naval Architecture, (transl. by Marta Ilić).
WATER AS A PRESSURE MEDIUM 7

Figure 1. Water density as a function of pressure and temperature. (Source:

https://pdfs.semanticscholar.org/0b72/75592e2d559d897a8668dc944ef7c4450728.pdf)

Figure 2. Relative mass, ρ (P)/ρ in function of pressure. (Source:

https://pdfs.semanticscholar.org/0b72/75592e2d559d897a8668dc944ef7c4450728.pdf)
WATER AS A PRESSURE MEDIUM 8

Specific heat

The specific heat at constant pressure is defined as the amount of energy required to
change the temperature of 1 kg of substance by 1°C and does not vary much in relation to
temperature and pressure (see Figure 3). The average values of specific heat at constant
pressure and at 40°C, 4.180 kJ/kg°C for water and 1.90 kJ/kg°C for mineral oil. This means
that water has a higher capacity (2.2 times) to absorb heat from mineral oil and therefore it will
take more time to warm up compared to the same amount of mineral oil for the same capacity
(Erik Trostmann, 2001).

Figure 3. Specific heat of water.

(Source:https://pdfs.semanticscholar.org/0b72/75592e2d559d897a8668dc944ef7c4450728.p
df)

Viscosity

Perhaps the biggest difference between oil and water lies in the viscosity of these two
fluids. Viscosity or internal friction is a feature of working flexibility to give resistance when
moving relative motion (slipping) of its parts (Gordić, 2007)2. Water at atmospheric pressure
and temperature of 20°C has a viscosity of 1cSt. The viscosity of the water is usually lower
than the viscosity of the mineral oil in less than 1/30. The low viscosity of water, which is
almost constant, is an advantage, which is reflected in low continuous losses. This is

2
Gordić, D., (2007). Power transfer with fluid. Kragujevac: Faculty of Engineering, (transl. by Marta Ilić).
WATER AS A PRESSURE MEDIUM 9

particularly effective for low power hydraulic systems, because they use less pumps and
smaller engines for feeding them. Oil-using systems require rehearsals and error simulations,
as the viscosity of the oil changes with the temperature. As for water, the only glycol additive
can change its viscosity, for a minimum of 3-5 cSt. In a pressure range of 1-1000 bar, and a
temperature range of 3°C-50°C, the water viscosity varies about 3 times, while in the same
pressure range and temperature range of 20°C-70°C, the viscosity of the oil varies by around
10 times (see Figures 4 and 5). This gives another advantage to a hydraulic system that uses
water in terms of speed and efficiency of the flow because it is more stable in a wider range of
operating temperatures than the hydraulic system using oil. However, the lack of low viscosity
is that the tendency of internal leakage is greater than in oil hydraulic systems, which requires
the development of hydraulic components with much less tolerance (Erik Trostmann, 2001).

Figure 4. Kinematic viscosity of water in function of temperature and pressure.

(Source:https://pdfs.semanticscholar.org/0b72/75592e2d559d897a8668dc944ef7c4450728.p
df)
WATER AS A PRESSURE MEDIUM 10

Figure 5. Variation of the kinematic viscosity of mineral oil with temperature and pressure.
(Source:https://pdfs.semanticscholar.org/0b72/75592e2d559d897a8668dc944ef7c4450728.p
df)

Possibility of using water hydraulics

Thanks to the significant advantages, water hydraulic systems are increasingly taking
the place of oil, pneumatic and electrical systems in many areas. New construction solutions
and continuous development have contributed to the fact that water hydraulic systems have a
wide range of applications in various industrial areas, such as:Thanks to the significant
advantages, water hydraulic systems are increasingly taking the place of oil, pneumatic and
electrical systems in many areas. New construction solutions and continuous development have
contributed to the fact that water hydraulic systems have a wide range of applications in various
industrial areas, such as:

 Food industry;
 Chemical and pharmaceutical industries;
 Mining industry;
 Steel industry;
 Nuclear industry;
 Wood processing;
WATER AS A PRESSURE MEDIUM 11

 Tubing processes;
 Moisturizing processes;
 Fire fighting systems;
 High pressure cleaners.

The following text will give some examples of the application of water hydraulic
systems in some industrial areas.

Food industry

One of the examples where hydraulic hydraulics are applied in the food industry is the
hamburger making machine (see Figure 6). With this machine all the necessary operations are
performed by the water hydraulic components. Two hydro-cylinders are driven by spiral
conveyors that insert meat into a bunker, where two larger hydro-cylinders suppress the meat
in forming molds. The molds move further, also by means of hydro-cylinders, to two hydro-
cylinders that push meat on one ribbon conveyor, which hamburgers take to the packer
machine. This machine can produce 18,000 hamburgers per hour. With this machine there is
no risk of contamination of the meat by working fluid (Krutz & Chua, 2005).

Figure 6. The machine for production hamburgers.

(Source:http://www.jfps.jp/proceedings/tukuba2005/pdf/key_02.pdf)
WATER AS A PRESSURE MEDIUM 12

Mobile hydraulic systems

All hydraulic functions of the garbage trucks (see Figure 7) are provided by hydraulic
hydraulic components: hydraulic cylinders for straight line movement, ie, opening / closing the
rear cover, pressing the garbage, lowering / lifting the container, etc. The high-pressure pump
is powered by the engine itself that uses natural gas as a fuel (Krutz & Chua, 2005).

Figure 7. Garbage truck. (Source:http://www.jfps.jp/proceedings/tukuba2005/pdf/key_02.pdf)

Here we can also mention the street cleaning machine (see Figure 8).

Figure 8. Street cleaning machine.

(Source:http://www.jfps.jp/proceedings/tukuba2005/pdf/key_02.pdf)
WATER AS A PRESSURE MEDIUM 13

Conclusion

At the beginning of the last century, the only working fluid used in hydraulic systems
was water or aqueous emulsions. The operating pressures were small, as well as the speeds.
The emergence of hydraulic systems that used mineral oil as a working fluid increases the
scope of hydraulics. Oil systems developed rapidly, so they almost completely replaced
hydraulic hydraulic systems. In the eighties of the last century, new areas of application, in the
automotive, food, and nuclear industries have created the need for improving hydraulic
hydraulics.

The starting points for these changes were growing distrust in oil hydraulics due to
increased fire risk and high environmental pollution. So, the working fluid must ensure: it is
non-flammable, does not pollute the environment and is biodegradable in a short period of
time.

All of the above mentioned leads us to the conclusion that water, and especially pure
water, is an interesting and attractive working fluid for hydraulics. However, the physical
properties of water differ considerably from the properties of mineral oil. For this reason, until
recently, there was a belief that high-pressure water systems would be difficult to produce and
cost a lot, but that's not the case. With the right choice of materials and design solutions, we
have been reliable and affordable systems.

Thanks to the significant advantages, water hydraulic systems are increasingly taking
the place of oil, pneumatic and electrical systems in many areas. New construction solutions
and continuous development have contributed to the fact that hydraulic hydraulic systems have
a wide range of applications in various industrial areas, such as: food industry, chemical and
pharmaceutical industry, mining industry, nuclear industry, etc.

This increase in the use of hydraulic hydraulics has largely been the result of increased
environmental care and the development of more sophisticated components.

The properties and lifespan of water hydraulic system components can be compared to
oil systems. Water hydraulic systems and their components are fully fireproof and give a high
level of hygiene (there is no risk of contamination of the product and the environment).

All this indicates that the future of hydraulic hydraulics is very good and that the water
can soon return to the top of the use in hydraulic systems.
WATER AS A PRESSURE MEDIUM 14

References

Gordić, D. (2007). Prenos snage fluidom. Kragujevac: Mašinski fakultet.

Jaklin, I. (2012). Hidraulični sistemi. Zagreb: Sveučilište u Zagrebu, Fakultet Strojarstva i

Brodogradnje.

Krutz, G., P., Chua. (2005). Trends in design of water hydraulics. Technical University of
Denmark: Department of Mechanical Engineering.

Trostmann, E. (1996). Water Hydraulics Control Technology. Technical University of

Denmark.

Trostmann, E. (2001). Tap Water as a Hydraulic Pressure Medium. Birkeroed: Technical

University of Denmark.