GENERAL CATALOG
Design 1
and we will get back to you.
Thank You!
Your enquiry has been received, We will get back to you shortly.
Introduction The Hydraulic Power Pack and Actuator System is engineered as a fully modular, skid-mounted electro-hydraulic solution delivering up to 300 kW of continuous power at pressures up to 250 bar. Built around a compact footprint, the skid incorporates vibration-isolated mounts, removable access panels, and integrated cable trays to simplify installation in constrained plant environments. Its core manifold block is CNC-machined from high-grade aluminum alloy, minimizing internal leakage paths and ensuring consistent flow distribution. The reservoir features internal baffling for rapid air/oil separation, sight-glass level indicators, and a 50 mm inspection port to facilitate visual checks and fluid sampling without system depressurization. Applications • Railway Fuel-Tank Filling: Provides automated, mass-based fueling with ±0.1 % accuracy via integrated load cells and interlocked valve sequences, preventing overfills and ensuring regulatory compliance for environmental emissions control. • Industrial Actuation & Test Benches: Supplies precise pressure and flow for dynamic load simulation up to 1 MN, servo-valve characterization, and endurance fatigue testing of valves and cylinders in R&D and production environments. • Mobile Offshore & Defense: Delivers ruggedized hydraulic power on vibration-isolated mounts, with marine-grade paint and corrosion-resistant fiƫngs, for subsea winches, deck machinery, and turret stabilization systems. • Aerospace Ground-Support: Powers test stands for flight-control actuators and engine accessory drives, featuring rapid thermal cycling through a glycol-water heat-exchanger circuit to validate components under extreme temperature profiles. Core Components Pumping Assembly • Variable-Displacement Axial Piston Pump: Up to 220 L/min at 250 bar, stepless control via a swashplate actuator driven by a digital servomotor for precise flow modulation. • Fixed-Displacement Auxiliaries: Two 100 L/min pumps engage through a pressure-sensing load-sense valve as demand increases; optional third pump provides N+1 redundancy. • Priority and Sequence Valves: Ensure uninterrupted minimum flow to critical servos; sequence valve manifold orchestrates fill, drain, and bypass operations during startup and shutdown. Reservoir & Filtration 2,000 L SS 304 Reservoir: Features internal cones to direct return oil toward the suction port, minimizing aeration; includes 5 kW immersion heater for low-temperature startups. Filtration Train: 10 μm ABS-rated primary filter with pressure-differential bypass, followed by a 3 μm secondary filter; a fine-coalescer module removes water and entrained air, and an optional electrostatic cleaner strips sub-micron contaminants to ISO 4406 classes 16/14/11 or better. Thermal Management • Shell-and-Tube Heat Exchanger: Rated 300 kW at 700 L/min with adjustable flow-control valves; provides ±1 °C temperature stability via RTD-feedback loop. • Cooling Tower Circuit: 95-ton nominal capacity with VFD-controlled fan and auto-purge drain; glycol-water loop option for glycol-based fluids or potable-water restrictions. • Dehydration & Degasification: Vacuum-degas module draws moisture-laden vapors, routed through a molecular-sieve dryer to maintain <50 ppm water content. Control & Monitoring • HMI/PLC Suite: Allen-Bradley ControlLogix or Siemens S7 plaƞorm with 10o color touchscreen, OPC UA and Profinet gateways, and built-in cybersecurity features (firewall, user-role access). • Data Logging & Analytics: Embedded Historian stores 1 year of 1 Hz data for pressure, temperature, flow, and mass; supports OPC HDA for remote trending and integration with digital-twin plaƞorms. • Alarms & Notifications: Configurable SLAs for high/low pressure, temperature excursions, filter differential, and mass thresholds; automatic SMS/email alerts and SCADA-level OPC DA tags for plant DCS integration. Maintenance & Serviceability • Quick-Change Filters: Spin-on housings with captive bolts; integrated differential gauges and bypass indicators enable “hot-swap” without system shutdown. • Modular Sub-Assemblies: Pump, heat-exchanger, and controller modules can be unplugged via multi-pin quick connectors, reducing mean time to repair (MTTR) to under 2 hours. • Predictive Diagnostics: Vibration sensors on pump bearings and motor shafts feed into the PLC’s predictive-maintenance block, issuing maintenance alerts based on MTTF algorithms. Customization & Options • Reservoir Variants: 1,000 L–5,000 L capacities; carbon-steel, SS 316, or polyurethane-lined for abrasive or corrosive fluids. • Fluid Compatibility: Supports mineral, fire-resistant (HFDU, HFC), and biodegradable hydraulic fluids with tailored elastomer seals. • Environmental & Safety Packages: ATEX/IECEx explosion-proof motors, SIL 3 rated safety PLC add-ons, cold-start packages with heat-trace lines, and sound-attenuating enclosures achieving <75 dBA at 1 m. Operating Highlights • Pre-Start: Automatic self-test of sensors and valve actuators; reservoir pre-heat to 40 °C in <15 min. • Filling Sequence: Load-cell feedback holds mass setpoint within ±0.02 %; valve manifold executes multi-stage fill profile to reduce surge. • Continuous Operation: Active filter regeneration cycle every 72 h, based on differential pressure; chiller compressor modulation maintains ±1 °C thermal band. • Shutdown & Safeguards: Controlled ramp-down of pump swashplate, followed by automatic purging of return lines to prevent residual pressure traps. Key Features • Precision Flow Control via digital swashplate actuation and load-sense logic • Superior Cleanliness to ISO 4406 ≤ 16/14/11 with electrostatic and coalescer stages • Energy Efficiency from VFD-driven pumps, fans, and insulation jackets • Advanced Diagnostics including vibration-based predictive-maintenance alerts • Safety-Certified to SIL 3 (optional) and ATEX Zone 1 standards • Rapid Serviceability with hot-swap filters and plug-and-play modules Technical Specifications
