SPECIFICATION PREFACE SHEET

DEPARTMENT:

SHEET 1 OF 11

Engineering / Mechanical

AREA: Grundartangi Reduction Plant

Spec.No: 00/05/TS011

REV: C1

STANDARD TECHNICAL
SPECIFICATION
FOR

HYDRAULIC SYSTEMS

This Standard Technical Specification is subject to change without prior notice. The most
current issue will at all times be located on the Nordural web site, www.nordural.is.

REV
A
C1

BY
TBA
EFB/G

DATE
18.10.2000
07.06.2004

CHKD

APPROVED

EFB

OJ

NORURL - ENGINEERING

REVISIONS
FOR REVIEW
Issued for construction

NORURL
NORDIC ALUMINUM

STANDARD TECHNICAL SPECIFICATION

00/05/TS 011 HYDRAULIC SYSTEMS

TABLE OF CONTENTS
SPECIFICATION PREFACE SHEET..................................................................................................... 1
1.

GENERAL ......................................................................................................................................... 3
1.1
1.2
1.3
1.4
1.5
1.6

2.

CONSTRUCTION DATA ................................................................................................................ 4

2.1
2.1.1
2.1.2
2.1.3
2.2
2.2.1
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.5
2.5.1
2.5.2
2.6
2.7
2.8
2.8.1
2.8.2
2.8.3
2.8.4
2.9
2.9.1
2.9.2
2.9.3
2.9.4
2.9.5

3.

NOMINAL PRESSURE ................................................................................................................... 3

ELECTRICAL REQUIREMENT ........................................................................................................ 3
SYSTEM SIMPLICITY .................................................................................................................... 3
PAINTWORK OF A HYDRAULIC SYSTEM ....................................................................................... 3
NOISE LEVEL ............................................................................................................................... 4
CE-CERTIFICATE ........................................................................................................................ 4

CONSTRUCTION DOCUMENTS AND ACCEPTANCE ......................................................................... 4

System drawings.................................................................................................................... 4
Drawing format..................................................................................................................... 4
Acceptance of a system design .............................................................................................. 4
THE FLUID, CHOICE AND TREATMENT ........................................................................... 4
Choice of fluid ....................................................................................................................... 4
FILTRATION ................................................................................................................................ 5
Location of the filters ............................................................................................................ 5
Filter arrangement ................................................................................................................ 5
Filter sizing ........................................................................................................................... 5
Added filtration (on request from Norurl)......................................................................... 5
THE RESERVOIR..................................................................................................................... 6
Construction .......................................................................................................................... 6
Capacity ................................................................................................................................ 6
Impermeability (on request from Norurl).......................................................................... 6
Equipment ............................................................................................................................. 6
Returns and drains ................................................................................................................ 7
THERMAL EXCHANGERS .................................................................................................... 7
Heating the fluid (on a request from Norurl) .................................................................... 7
Fluid cooling ......................................................................................................................... 7
HYDRAULIC PUMPS ..................................................................................................................... 8
HYDRAULIC CYLINDERS .............................................................................................................. 8
HYDRAULIC VALVES ................................................................................................................... 8
Directional valves ................................................................................................................. 8
Main pressure relief valve..................................................................................................... 9
Pressure-, isolator- and flow valves...................................................................................... 9
Assembly on a drilled manifold ............................................................................................. 9
PIPING AND FITTINGS .............................................................................................................. 10
Hydraulic piping ................................................................................................................. 10
Hydraulic hoses.................................................................................................................. 10
Hydraulic fittings and support ............................................................................................ 10
Expansion............................................................................................................................ 10
Pipe welding........................................................................................................................ 10

ASSEMBLY & CLEANING ......................................................................................................... 11

3.1

ASSEMBLY OF HYDRAULIC INSTALLATIONS ............................................................. 11

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STANDARD TECHNICAL SPECIFICATION

00/05/TS 011 HYDRAULIC SYSTEMS

NORDIC ALUMINUM
3.2

1.

CLEANING OF HYDRAULIC INSTALLATION AFTER ASSEMBLY ON THE SITE.... 11

GENERAL
The purpose of this standard is to show the constructive arrangements for the
studies and developments of hydraulic installations within Norurl Aluminium
Plant.
The specific conditions for the operating of an aluminium plant have led
Norurl to specify the constructive arrangements essential to the proper
functioning of hydraulic installations.
In this Document the following words and expressions shall have the meaning
hereby assigned to them except where the context otherwise requires:
Engineer:
The Owner or any person or organisation employed or engaged at
any time by the Owner and authorised by the Owner, in writing, from time to
time to act on behalf of the Owner in the execution of the items covered by this
Document, in whole or in any part, for any or all purposes provided in this
Technical Specification.
Owner:
Norurl hf (Nordic Aluminum Corporation Ltd.), an independent
legal entity owned by Century Aluminum.

1.1

NOMINAL PRESSURE
The nominal pressure is restricted to 210 bars maximum. Higher system
pressure shall be endorsed by The Engineer.

1.2

ELECTRICAL REQUIREMENT
As stated in Norurl Standard Technical Specifications for Electrical
Equipment

1.3

SYSTEM SIMPLICITY
Most of the hydraulic applications of an aluminium plant do not require
sophisticated systems. Norurl would like the suppliers of hydraulic circuits to
aim for simplicity in their design and reserves the right to refuse any system
considered to be more sophisticated than asked for.

1.4

PAINTWORK OF A HYDRAULIC SYSTEM

All parts of a hydraulic system shall be sandblasted, where required, and
painted in accordance to Norurl Standard Technical Specifications for
Surface treatment and Painting, 00/03/TS001. During the surface treatment and
the paintwork label plates, indicating type and serial numbers of parts, shall be
covered.

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NORURL

STANDARD TECHNICAL SPECIFICATION

00/05/TS 011 HYDRAULIC SYSTEMS

NORDIC ALUMINUM

1.5

NOISE LEVEL
Noise level from a hydraulic system shall not exceed Icelandic OSHA
requirements.

1.6

CE-CERTIFICATE
All equipment delivered to Norurl shall have CE-Certificate from the supplier.

2.

CONSTRUCTION DATA

2.1

CONSTRUCTION DOCUMENTS AND ACCEPTANCE

2.1.1 System drawings

The supplier of a hydraulic system shall deliver a system drawing, according to
ISO 1219, with at least following informations:
Complete function of the hydraulic system.
Informations about supplier
Part list involving all components with information of
o Component description
o Quantity
o Producer
o Part type
o Tube sizes
2.1.2 Drawing format
The size of the drawing format shall by according to EN ISO 5457. The supplier
shall deliver drawings on computerised form on one of following type:
DWG
DXF
PDF
The format DWG is preferred.
2.1.3 Acceptance of a system design
Before construction of a hydraulic system the supplier shall get an acceptance for
the system from the Engineer.

2.2

THE FLUID, CHOICE AND TREATMENT

2.2.1 Choice of fluid

Hydraulic systems shall be designed to operate, wherever possible, with

petroleum based hydraulic fluid VG46, according to DIN 51519.
Fire resistant fluids (ESSO FireEX or equalent) shall be used where
petroleum based fluids pose a fire hazard due to high temperature
conditions or unguarded sources of ignition.
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NORDIC ALUMINUM

2.3

STANDARD TECHNICAL SPECIFICATION

00/05/TS 011 HYDRAULIC SYSTEMS

Before resorting to using a fire resistant fluid, the arrangement of the

elements of the hydraulic system must be examined and removed from
danger zones.
If it is essential to use such a fluid, the specific precautions for its use, as
compared to the use of a mineral oil, must be taken into consideration.
This includes for example the type of sealings in all components in a
hydraulic system.
The Engineer shall accept the choice of fluid.

FILTRATION

2.3.1 Location of the filters

Filtration systems that only have filters on the suction side of the pumps
are not acceptable.
Every hydraulic installation shall be equipped with a system of return
filters.
In hydraulic systems, with sensitive control valve systems, high pressure
filters are required on the pressure side of the pump.
The drain collector also has a filtration system.

2.3.2 Filter arrangement

All filters must be easily accessible and able to change filter elements
with a minimum loss of oil and time.
All filters shall be equipped with visual pressure drop indicator.
For continuously operating installations that cannot be stopped for filter
changes, filters shall be installed in duplicate, mounted in parallel. Filter
switching takes place using isolation valves, which may have proximity
safety devices confirming valve position and authorizing the start up of
the pumps.

2.3.3 Filter sizing

On the return side of the system the filters shall be designed for at least
two times the peak return flow (including discharge of accumulators and
jacks) with a load loss of 10 to 35 kPa and having filtration ratio of 10-20
micron absolute value.
On the high-pressure side of the circuit the filters shall be designed for at
least twice the maximum-flow of the pump(s) with a load loss of 70 kPa
(complete filter, new filter element) and having filtration ratio of 10-20
micron absolute value.

2.3.4 Added filtration (on request from Norurl)

For reservoirs with a capacity of 600 litres or more, or because of a

request from Norurl, a permanent separate filtration system (separate
from the return system) shall be installed. The flow rate (in l/min) of the
filtration system shall be at least 5% of the volume of the reservoir.
Filters shall be sized for at least twice the flow.
Maximum filtration ratio 3 micron absolute value for added filtration.
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NORDIC ALUMINUM

2.4

STANDARD TECHNICAL SPECIFICATION

00/05/TS 011 HYDRAULIC SYSTEMS

THE RESERVOIR

2.4.1 Construction

The reservoir shall be completely welded with inspection openings

located on the sides or on the top. The openings shall be sealed with a
reusable joint that is suitable for the fluid being used.
Reservoirs shall be made of S 235 steel, sandblasted and coated inside
with an anti-oxidising substance that is compatible with the fluid.
The reservoir shall be splitted in two sections such that suction and
return connections are in separate section. Opening between the
sections shall be in the low-level of the reservoir and opening sizes shall
be in such way that it do not detain the flow to the suction connection.
All reservoirs shall be equipped with two connections of a size that can
manage flow rate (in l/min) at least 10 % of the volume of the reservoir
allowing mobile equipment for regenerating oil to be added. Connections
shall be one (1) in the lower part of the reservoir and one (1) upstream
from the return filter. Shut-off valve shall be installed to the connections.

2.4.2 Capacity
Reservoir capacity for fluid VG46 shall be not less than:
The maximum system volume, or
Three (3) times the pump capacity in l/min.
Reservoir capacity for Fire resistant fluid shall be not less than:
Four (4) times the pump capacity in l/min.
2.4.3

Impermeability (on request from Norurl)

On special request from Norurl the tanks shall be impermeable.
A hydraulic compensator or expansion bladder is used with outside
mounting and bladder protection.
In order to avoid bladder damage should oil loss be too great, the
reservoir is equipped with a breather with a non-return valve and bypass flap calibrated at a minimum of 200 kPa.
The minimum filtration-threshold for the breather is 3 microns.
Should the volume vary beyond the maximum of the compensator
manufacturers range, the reservoirs are pressurized with nitrogen to a
pressure of 10 kPa.

2.4.4 Equipment
A reservoir shall be equipped with
A visual level display with electrical low-level indicator, activated when at
least 40% of the tank volume is remaining in the tank, and by that
shutting down the hydraulic pump.
Heat sensor activated when the oil temperature reaches 80C.
A drainage pipe with a ball valve
An open spillage pan placed under the reservoir and pump to
accumulate all spillage. This pan shall be able to be emptied by gravity.
Air breather with filtration-threshold of 3 micron. The air that enters shall
be dried using a cartridge of a drying product.
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NORDIC ALUMINUM

STANDARD TECHNICAL SPECIFICATION

00/05/TS 011 HYDRAULIC SYSTEMS

Fill connections shall be placed so that the fluid passes through the
return filter. Filling takes place using a hydraulic quick coupling 1/2"
connection.

In general, the dismantling of the accessories or equipment must be possible

without emptying the oil.
2.4.5

Returns and drains

Returns and drains from the system must always be attached to the reservoir
below the minimum level.

2.5

THERMAL EXCHANGERS
The normal working temperature of the hydraulic circuit must be between 40
and 70C. Working fluid heating and cooling systems shall be used to ensure
this temperature.

2.5.1 Heating the fluid (on a request from Norurl)

To avoid all local oil carbonisation, electrical heating tubes that can
produce about 0.7 W/cm2 shall be used.
The tubes must be carefully installed on the walls of the reservoir and
must be able to be dismantled without having to empty the reservoir
(well or sheath). They shall be located halfway between the bottom of
the reservoir and the minimum- oil level.
Low speed oil circulation (using an auxiliary pump) is recommended
(stirring of the oil to prevent having hot and cold areas).
Heating tubes that produce more than 0.7 W/cm2, but less than 2
W/cm2 can only be used with the Engineer approval. This size of heating
tubes requires low speed oil circulation and suitable baffles in the
reservoir so as to be properly submerged in oil. An electrical safety
device allows the tubes to be turned on only if the auxiliary circulation
pump is on.

The heating tubes shall operate on conveniently located thermostats

If T < 10C, the heating tubes go on,
A thermostat set at 10C authorizes the start up of the station,
A thermostat to turn off the heating tubes at a temperature of 30C,
Safety thermostat set at 35C, designed to compensate for operating
failure by the maximum thermostat.
2.5.2

Fluid cooling
If the natural cooling of the designed hydraulic system is insufficient an external
cooling shall be added.
The cooling method preferred is by air cooled heat exchanger.
For installations under 30 kW of power, the cooler shall be mounted on
the return line to the reservoir. Depending on requirements it may let
either all or a part of the oil in circulation to pass through.

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2.6

STANDARD TECHNICAL SPECIFICATION

00/05/TS 011 HYDRAULIC SYSTEMS

In any event, all returns from the pressure limiters shall pass through the
cooler.
A thermostat valve shall regulate the cooling of the hydraulic fluid. This
valve shall starts up cooling if the temperature rises higher than 55C
and maintains cooling until a temperature of 40C is reached.
Major installations over 30 kW of power shall be equipped with a special
cooling circuit that is similar in principle to the heating system.

HYDRAULIC PUMPS
The choice of the type of pump depends on the specified pressure limits
Vane pumps:
up to 10 MPa (used only with special permission)
Gear pumps:
up to 15 MPa
Piston pumps: all pressures
Rotation speed is limited to 1500 rpm, including in the case of thermal motor
drive.
Maximum underpressure on pump suctions -10 kPa.
Pumps shall be mounted sideward or under the reservoir with an
acceptable access to the pump.
A shut-off valve shall be placed on the suction pipe between pump and
reservoir.
In case of specific space problems a pump can be mounted on top of the
reservoir, with special permission from the Engineer.
Only small gear pumps can be immersed in the reservoir.
A pump is mounted on the electric motor using a lantern and coupling.
When using double identical pumps, each pump is mounted on its own
electric motor

2.7

HYDRAULIC CYLINDERS

2.8

Hydraulic cylinders shall have heavy-duty or mill-type design and

construction.
Cylinder sizes and rod diameters shall be per CETOP recommendations.
The piston rods are made of high strength steel, hard chrome plated
bars
The cylinder tubes are made of hard chrome plated tubes.
Cylinders subject to external deceleration loads shall be equipped with
tapered cushions having manually adjustable cushion valves. The
adjustment screws must be accessible.
On cylinders with movement in vertical direction, a load control valve
shall be installed at the lower end of the cylinders to protect it from
hose/piping failure.
In case of hose failure the cylinder shall be locked in position.

HYDRAULIC VALVES

2.8.1 Directional valves

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Valves shall be of proven heavy duty industrial type.

Valves shall be sub-plate mounted wherever possible.
The number of installation planes, for mounting sub-plate valves on an
assembly base, is restricted to five, taking into account the load losses
produced by simultaneous movements.
The unit must be rigid enough to allow it to be handled and eliminate all
vibration.
The unit must be designed and set up in such a way that all components
are easily accessible.
Solenoid operated valves shall be equipped with indicator light and
manual override.

2.8.2 Main pressure relief valve

In all hydraulic systems a main pressure relief valve shall be mounted on the
pressure side of the pump. The purpose of this valve is to:
Set the maximum pressure level for the total hydraulic system.
Manage the total flow from the pump in case of the pressure level reaches
the maximum adjustment.
In a system with installed variable pump this valve is unnecessary if the flow from
the pump will be set to zero when the maximum pressure level is reached.
2.8.3 Pressure-, isolator- and flow valves

Valves shall be of proven heavy duty industrial type.

On-line assembly shall be used rather than component stacking.
In case of component stacking the maximum recommended stacking is 2
components plus the distributor.

2.8.4 Assembly on a drilled manifold

The type of assembly must enable each receiver (cylinder, motor etc) to
be isolated from the control circuit.
No element (speed control valve etc) must be located inside the block.
The diameter of the drilling holes must be equal at least to the nominal
diameter of the connected piping in order to guarantee a minimum of
toad loss.
The connections must not display any widening (accumulation of
impurities) or narrowing (local load losses).

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2.9

PIPING AND FITTINGS

2.9.1 Hydraulic piping

2.9.2

Hydraulic piping shall be yellow galvanised seamless cold drawn

precision steel tubes, E235, according to standard EN 10305-1 or EN
10297-1.
Pipe bends shall be used in place of elbows where possible where the
sizes of the bending radius shall not be smaller than 3 times the tube
diameter.
Piping shall be sized to limit fluid velocity to 4 m/s in flow lines and 1,5
m/s in return and suction lines.
Rigid piping shall have a factor of safety of at least 4
Piping shall be installed to permit removal without disturbing circuit
components and without excessive bending or springing.
Thread tape or sealing compound shall not be used.
The number of connections and joints in an installation must be kept to a
minimum.

Hydraulic hoses
In particular, flexible tubing shall be used only
Between mobile pieces of equipment
To facilitate the replacement of interchangeable components
To reduce the transmission of mechanical vibrations and/or noise.

Flexible hoses shall have a factor of safety of at least 4.

2.9.3 Hydraulic fittings and support

Hydraulic fittings shall be yellow galvanised cutting ring fittings according

to standard EN ISO 8434-1 and DIN 2353.
Pipe supports shall be set in compliance with the E48-201 standard
paragraph 7.2.9.
All connections must be accessible. In particular do not superpose layers
if this makes access to the connections in lower layers impossible.

2.9.4 Expansion
The connections shall be spread out to create a line that is better for expansion.
2.9.5 Pipe welding
All pipe welding on hydraulic tubes is forbidden.

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3.
3.1

ASSEMBLY & CLEANING

ASSEMBLY OF HYDRAULIC INSTALLATIONS

3.2

The hydraulic station shall be entirely assembled, tested and cleaned by

the supplier. The piping is prepared entirely on the site, keeping the
number of connections to a minimum, in compliance with 2.9 of this
specification.
Before using the tubes, the internal protective grease shall be dissolved
using the appropriate solvent.

CLEANING OF HYDRAULIC INSTALLATION AFTER ASSEMBLY ON

THE SITE

Before cleaning, all the components of the installation shall be isolated

(dismantling of components, temporary deviations, etc).
Cleaning shall be done with undoped mineral oil that is compatible with
the final fluid using a specific independent pump group.

Operating parameters during cleaning

Reynolds number higher or equal to 3000, this value is reached
through sufficient speed and temperature conditions that must be
backed by the cleaning company.

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