Specification of Hydraulic Power Pack and Pneumatic Service Unit (FRL Unit)

Specification of Hydraulic Power Pack and Industrial Hydraulics and Pneumatics,
Pneumatic service unit (FRL unit) Semester 6
Chapter 1
Introduction
____________________________________________________
 Hydraulic Power Pack:-
In basic terms, a hydraulic power pack is a self-contained unit that consists

mainly of a motor, a reservoir and a hydraulic pump. Using fluid to
transmit power from one location to another, hydraulic power packs can generate
massive amounts of power which can be used to drive hydraulic machinery.
When heavy lifting or repeated directional force is required, hydraulic power
packs offer the perfect solution, drawing their power from ratios of area and
pressure as defined by Pascal’s law of physics.
Hydraulic power packs will have the following components are;
1. A Hydraulic reservoir
2. A Regulators
3. A pump
4. A Motor
5. Pressure supply lines
6. Relief lines.
 Pneumatic service unit (FRL unit):-
Filter, regulator, and lubricator (FRL) compressed air systems are used to
deliver clean air, at a fixed pressure, and lubricated (if needed) to ensure proper
pneumatic component operation and increase their operation lifetime. The air
supplied by compressors is often times contaminated, over pressurized, and
non-lubricated meaning that an FRL unit is required to prevent damage to
equipment.
Components of FRL unit:-
1. FILTER
Filtering compressed air is widely regarded as the initial phase of air
preparation. To allow machinery and pneumatic components to work at their
optimum, they must be fed with clean, filtered air that is free of dust, water and
other particles. Various filtration levels are available between 5 and 40 microns.
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VIVA COLLEGE OF DIPLOMA ENGG & TECH, MECHANICAL ENGG Submitted by: Mr. Paren Trivedi
2. PRESSURE REGULATORS
Air pressure regulators benefit the FRL boxset in many ways. Firstly, and most
importantly it provides an element of safety. Subsequent to this, it also helps to
reduce costs. The role of a regulator is to control the air pressure to air tools, air
gauging equipment and cylinders. The air pressure is regulated by a spring
which acts through a diaphragm.
3. PNEUMATIC LUBRICATORS
Like pressure regulators, the lubricator function of an FRL unit ensures that
the air is dosed with a small amount of lubrication oil to help pneumatic
components work effectively. Lubricators ensure that the correct amount of oil
is being used to reduce the friction between moving components. This feature is
very important to ensure a long machinery life span.
2
Chapter 2
Project Details
____________________________________________________
 Hydraulic Power Pack:-
 Description
The HPS Standard construction power packs are designed to utilise a standard
range of modular components. This offers a power pack that can be easily
specified and maintained.
 Design
- Steel Tank 16, 30, 55, 75, 100 & 180 Litre
- Aluminium Gear pumps
- Pressures to 250 bar
- Flow rates to 100 litres/minute
- Suction filter 90 micron
- Return filter 25 micron
- Submerged Pump
- Cetop subplate options
- 1 phase to 3kW
- 3 phase to 30kW
3
 Quality
- 100% functional testing
- Tanks with painted finish
- Motors IEC frame B5 IP55
- Supplied with C of C
 Ordering Code
HPS - S - G4 - 6C - V - P - 3 - 16C - D - XXXX
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 Motor Selection
Motor power Frame Height “D”
D = 0.55kW 80a 250mm

E = 0.75kW 80b 250mm
F = 1.1kW 90S 264mm
G = 1.5kW 90L 288mm – maximum of 110V 1phase
H = 2.2kW 100La 322mm
I = 3.0kW 100Lb 322mm - maximum of 240V 1phase
J = 4.0kW 112M 353mm
K = 5.5kW 132S 380mm
L = 7.5kW 132Ma 421mm
M = 11kW 160M 496mm
N= 15kW 160L 496mm
O = 18.5kW 180M 539mm
P = 22kW 180L 539mm
Q = 30kW 200L 577mm
 Power pack overview
5
Pump size cc
Tank A B C Q M Motor size
(litre per minute)
410 325 310 364 270 from 1cc (1.45 lpm) from 0.55kW
16 litre
mm mm mm mm mm to 9.8cc (14.2 lpm) to 1.5kW
from 3.15cc (4.5 from 1.1kW
470 375 340 428 312
30 litre lpm) to 4kW
mm mm mm mm mm
to 14cc (20.3 lpm)
from 6.3cc (9.1 from 2.2kW
600 470 370 548
55 litre 401mm lpm) to 22cc (31 to 7.5kW
mm mm mm mm
lpm)
from 12cc (17.4 from 4kW
600 470 460 548 401
75 litre lpm) to 32cc (46 to 7.5kW
mm mm mm mm mm
lpm)
from 12cc (17.4 from 4kW
100 675 520 510 625 455
lpm) to 36cc (52 to 22kW
litre mm mm mm mm mm
lpm)
180 805 620 560 755 555 from 20cc (29 lpm) from 7.5kW
litre mm mm mm mm mm to 60cc (87 lpm) to 30kW
 Pump Selection
Pump No, Displacement cc/rev Flow at 1450rpm litres/minute Max Pressur bar
1C 1 1.45 250
2C 1.25 1.8 250
3C 1.6 2.3 250
4C 2.0 2.9 250
5C 2.5 3.6 250
6C 3.15 4.5 250
7C 3.65 5.3 250
8C 4.2 6.1 250
9C 5.0 7.2 250
10C 6.1 8.8 200
11V 9.8 14.2 180
20C 6.3 9.1 250

21C 8.2 11.8 250
22C 10 14.5 250
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23C 11.3 16.4 250

24C 12 17.4 250
25C 14 20.3 250
26C 15 21.7 250
27C 16 23.2 250
28C 19 27.5 200
29C 22 31 180
30C 20 29 250
31C 25 36 250
32C 28 40 250
33C 32 46 250
34C 36 56 250
35C 42 60 230
36C 46 66 230
37C 50 72 200
38C 55 79 200
39C 60 87 180
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 Hydraulic Circuit
8
 Pneumatic service unit (FRL unit):-
DETAILED SPECIFICATIONS OF "FILTER/REGULATOR +

LUBRICATOR (FRL UNIT) :-
 Symbol of FRL unit:-
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VIVA COLLEGE OF DIPLOMA ENGG & TECH, MECHANICAL ENGG Submitted by: Group 111-120
I. COMPLYING STANDARDS :-
1) Filter should comply with ISO 5782-1 standard.
2) Regulator should comply with ISO 6953-1 standard.
3) Lubricator should comply with ISO 6301-1 standard.
II. TECHNICAL DETAILS :-
1) Medium : Compressed air
2) Mounting : Suitable for line, wall or bracket mounting.
3) Connection Size : 1/2" (inch)
4) Flow rate : Not less than 3700 lpm.
5) Working pressure range : 0 to 10 bar
6) Filter element : 40 microns
7) Drain type : Automatic drain facility.
8) Filter bowl capacity : Not less than 40 cc
9) Temperature range : 5-60 Deg Celsius
10) Lubricator bowl capacity : Not less than 75 cc
11) Filter & Regulator should be a combined unit & lubricator as a separately
attached unit.
12) Easy removal/re-fixing of filter & lubricator bowl should be possible by 90
deg., turn of bowl
13) Bowl guard should be provided.
14) Automatic draining facility should be provided.
15) Built in pressure gauge should be provided along with option for connecting it
to external pressure gauge.
16) Lockable type pressure adjusting knob should be provided.
17) Safety 'lock ring' should be provided to lock the bowl.
18) Make : Festo / Schrader / Shavo Norgren
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III. MATERIAL OF CONSTRUCTION :-

1) Housing : Aluminium alloy
2) Filter bowl : Transparent polycarbonate bowl.
3) Adjusting knob : POM
4) Filter element : Sinter bronze
5) Seals : Nitrile
IV. EVALUATION CRITERIA OF THE OFFERS :-
1) Offers from OEM / Authorized dealers of OEM / vendors who source the items
directly from OEM's or authorized dealers only will be accepted.
2) Authorized dealers should enclose a valid dealership certificate along with their
offer.
3) Vendors sourcing the items directly from OEM's or authorized dealers should
confirm in their offer for submission of documentary proof of evidence (towards
purchase of items directly from OEM / authorized dealers) along with supply of
items.
4) Technical data sheets or other relevant technical details & catalogues should be
submitted along with the offer.
V. ACCEPTANCE CRITERIA :-
1) Items should be supplied in a neat original packaging of the OEM.
2) The supplied items will be inspected (visual check for defects & functional
testing) at M/s NFC, Hyderabad. Acceptance will be given only after satisfactory
completion of this testing.
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Chapter 3
Conclusion
____________________________________________________
Studied about the specification of Hydraulic Power Pack and its Symbol. Also,
Studied about the specification of Pneumatic service unit (FRL unit) and its
Symbol.
Reference
https://www.hydraproducts.co.uk/Hydraulic-Power-Packs
https://www.relatedfluidpower.com/products/hydraulic-power-packs/
https://tameson.com/frl-filter-regulator-lubricator.html
https://www.researchgate.net/figure/Symbol-of-FRL-Unit_fig9_257941906.
12

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Specification of Hydraulic Power Pack and Industrial Hydraulics and Pneumatics,

Pneumatic service unit (FRL unit) Semester 6

In basic terms, a hydraulic power pack is a self-contained unit that consists

 Pneumatic service unit (FRL unit):-

Components of FRL unit:-

HPS - S - G4 - 6C - V - P - 3 - 16C - D - XXXX

Motor power Frame Height “D”

D = 0.55kW 80a 250mm

20C 6.3 9.1 250

23C 11.3 16.4 250

 Pneumatic service unit (FRL unit):-

DETAILED SPECIFICATIONS OF "FILTER/REGULATOR +

 Symbol of FRL unit:-

III. MATERIAL OF CONSTRUCTION :-

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