CHAPTER 9
Accumulators
9.1 Introduction
A hydraulic accumulator is a device that stores the potential energy of
an incompressible fluid held under pressure by an external source against
some dynamic force. This dynamic force can come from different sources.
The stored potential energy in the accumulator is a quick secondary source of
fluid power capable of doing useful work.
There are three basic types of accumulators:
1. Weight–loaded or gravity accumulator: Schematic diagram of weight
loaded accumulator is shown in Figure (9.1). It is a vertically mounted
cylinder with a large weight. When the hydraulic fluid is pumped into it, the
weight is raised. The weight applies a force on the piston that generates a
pressure on the fluid side of piston. The advantage of this type of accumulator
over other types is that it applies a constant pressure on the fluid throughout
its range of motion. The main disadvantage is its extremely large size and
heavy weight. This makes it unsuitable for mobile application.
Fig. (9.1): Dead weight accumulator
2. Spring-loaded accumulator: A spring-loaded accumulator stores energy
in the form of a compressed spring. A hydraulic fluid is pumped into the
accumulator, causing the piston to move up and compress the spring as
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shown in Figure (9.2). The compressed spring then applies a force on the
piston that exerts a pressure on the hydraulic fluid.
This type of accumulator delivers only a small volume of oil at
relatively low pressure. Furthermore, the pressure exerted on the oil is not
constant as in the dead-weight-type accumulator. As the springs are
compressed, the accumulator pressure reaches its peak, and as the springs
approach their free lengths, the accumulator pressure drops to a minimum.
Fig. (9.2): Spring–loaded accumulator.
3. Gas-loaded accumulator: A gas-loaded accumulator is popularly used in
industries. Here the force is applied to the oil using compressed air.
Schematic diagram of a gas loaded accumulator is shown in Figure (9.3). A
gas accumulator can be very large and is often used with water or high water-
based fluids using air as a gas charge. Typical application is on water turbines
to absorb pressure surges owing to valve closure and on ram pumps to
smooth out the delivery flow. The exact shape of the accumulator
characteristic curve depends on pressure–volume relations:
• Isothermal (constant temperature): This occurs when the expansion or
compression of the gas is very slow. The relationship between absolute
pressure P and volume V of the gas is constant:
P.V constant (9.1)
• Isentropic (adiabatic processes): This is where there is no flow of energy
into or out of the fluid. The law that the gas obeys is given by
P.V constant , where the ratio of specific heat and is approximately
equal to 1.4.
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• Polytropic: This is somewhere between isothermal and isentropic. This gas
change is governed by the law P.V n constant , where n is somewhere
between 1 and 1.4 and is known as the polytropic coefficient.
Fig. (9.3): Gas–loaded accumulator
There are two types of gas-loaded accumulators:
• Non-separator-type accumulator: Here the oil and gas are not separated.
Hence, they are always placed vertically.
• Separator-type accumulator: Here the oil and gas are separated by an
element. Based on the type of element used to separate the oil and gas, they
are classified as follows:
(a) Piston–type accumulator: Schematic diagram of a piston type
accumulator is shown in Figure (9.4). It consists of a cylinder with a freely
floating piston with proper seals. Its operation begins by charging the gas
chamber with a gas (nitrogen) under a pre-determined pressure. This causes
the free sliding piston to move down. Once the accumulator is pre–charged, a
hydraulic fluid can be pumped into the hydraulic fluid port. As the fluid
enters the accumulator, it causes the piston to slide up, thereby compressing
the gas that increases its pressure and this pressure is then applied to the
hydraulic fluid through the piston. Because the piston is free sliding, the
pressure on the gas and that on the hydraulic fluid are always equal.
324
Fig. (9.4): Piston–type accumulator
(b) Diaphragm accumulator: In this type, the hydraulic fluid and nitrogen
gas are separated by a synthetic rubber diaphragm. Schematic diagram of
diaphragm accumulator is shown in Figure (9.5). The advantage of a
diaphragm accumulator over a piston accumulator is that it has no sliding
surface that requires lubrication and can therefore be used with fluids having
poor lubricating qualities. It is less sensitive to contamination due to lack of
any close–fitting components.
Fig. (9.5): Diaphragm–type accumulator
325
(c) Bladder accumulator: It functions in the same way as the other two
accumulators. Schematic diagram of bladder accumulator is shown in Figure
(9.6). Here the gas and the hydraulic fluid are separated by a synthetic rubber
bladder. The bladder is filled with nitrogen until the designed pre–charge
pressure is achieved. The hydraulic fluid is then pumped into the
accumulator, thereby compressing the gas and increasing the pressure in the
accumulator. The port cover is a small piece of metal that protects the bladder
from damage as it expands and contacts the fluid port.
Fig. (9.6): Bladder–type accumulator
In an accumulator, at any point of time, we either compress a pre-
charged gas or allow it to expand. This compression or expansion brings
about a status change in the gas, which is governed by the perfect gas
equation:
P.V m R T
where: P the absolute pressure in bar,
V the gas volume in m 3 ,
m the mass in kg
R the universal gas constant. (The most common gas used in
industry is nitrogen.) For the particular gas and the accumulator, the value of
mR is constant and the gas equation is written as:
PV
constant
T
When the change takes place over a long period of time, the temperature of
the gas remains constant and such a change is called isothermal, resulting in
the equation:
PV constant
326
P1V1 P2V2 P3V3
When the change occurs instantaneously, there is no time for heat transfer
from the work to the environment. Such a change is called isentropic or
reversible adiabatic and is given by:
P1V1 P2V2 P3V3
All changes between isothermal and isentropic are called polytropic,
P1V1n P2V2n P3V3n
The pressure–volume diagram shown in Figure (9.7) helps us to
understand how the volume variation as a function of pressure depends on the
value of the polytropic exponent n that for nitrogen is contained within the
limits 1 n 1.4 . The value of n is taken to be equal to 1 if the compression
and expansion process takes place under the isothermal process. For adiabatic
conditions, the value of n is taken equal to 1.4.
Isothermal conditions can be considered to exist if the accumulator is
used as a volume compensator, leakage compensator and pressure
compensator or as a lubrication compensator. In all other cases, such as
energy accumulation, pulsation damping, emergency power source, dynamic
pressure compensator, shock absorber, hydraulic spring, etc., expansion and
compression process may be considered to take place under “adiabatic”
conditions. Generally, the adiabatic condition is considered to exist if the
compression or expansion period is less than 3 mm .
Fig.(9.7): Pressure–Volume diagram.
9.2 Accumulator Selection
327
After ascertaining the type of accumulator that is appropriate for the
purpose envisaged, what remains is determining the volume of the form of
“high pressure fluid.” Accumulators are manufactured to a variety of pressure
ratings and the one chosen should be rated for a pressure more than the
maximum system working pressure P3 .
Fig. (9.8): Accumulator charging and discharging process
Process from (1) to (2) is charging process
Process from (2) to (3) is discharging process
P1 Initial Precharge Pressure
P2 Maximum System Pressure
P3 Minimum System Pressure
V1 Accumulator Volume
V V3 V2 =Maximum Volume of Oil Accumulator
However, the values of the following basic parameters should be established
before proceeding further:
Working pressures P2 and P3 . The value of P3 is found from the ratio
P3
4 . The maximum gas precharge pressure is found from the relationship
P1
P1 0.9 P2 or P1 0.25P2 . The gas pre-charge pressure must be as close as
possible to the minimum working pressure P2 to obtain maximum storage.
Special values for P1 are used in pulsation damping and shock absorber
applications P1 0.8P2 . Other parameters to be determined are the volume
of fluid V that needs to be stored V 0.75 V1 , the maximum required
flow rate and the operating temperature.
328
9.2.1 Sizing Accumulators for Isothermal Charging and Discharging
(i) Isothermal Charging
For isothermal condition, the Boyle–Mariotte law can be rewritten in
terms of V1 and V2 as:
P .V Constant
P1 V1 P2 V2
P
V1 2 V2
P1
(ii) Isothermal Discharging
P .V Constant
P2 V2 P3 V3
P
V3 2 V2
P3
The difference between V3 at the minimum operating pressure P3 and V2 at
the maximum operating pressure P2 gives the amount of the stored fluid V .
Thus,
V3 V2 V
P2
V2 V2 V
P3
P
V2 2 1 V
P3
V
V2
P2
1
P3
Then
P
V1 2 V2
P1
P V V
V1 2 V1
P1 P2 P1 P1
1
P3 P3 P2
329
In the above equations, V2 and V3 are air volumes at the pressures P2 and P3 ,
and V1 is the air precharge volume at the pressure P1 in liters. It is the
maximum volume of gas that can be stored in the accumulator. The size of
the accumulator, while conforming to the standard available sizes, should be
at least 5 10% more than this volume V1 . Any increase in the value of
V results in a corresponding increase in the size of the accumulator.
Likewise any decrease in the value of P1 or the value of P2 P3 requires an
accumulator of higher volume.
9.2.2 Sizing Accumulators for Adiabatic Charging and Discharging
Starting from the basic formula P1V1 P2V2 P3V3 , it can be shown
that for adiabatic conditions, the values of maximum nitrogen volume V1 at
the precharge pressure P1 and the stored volume of oil are given by the
following:
(i) Adiabatic Charging
It can be shown that for adiabatic conditions, the values of maximum
nitrogen volume V1 at the precharge pressure P1 :
P .V Constant
P1 V1 P2 V2
P
V1 2 V2
P1
1
P
V1 2 V2
P1
(ii) Adiabatic Discharging
P V Constant
P2 V2 P3 V3
P2 V2 P3 V3
1
P
V3 2 V2
P3
The stored volume of oil is given by the following:
V3 V2 V
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1
P2
V2 V2 V
P3
1
P2
V2 1 V
P3
V
V2 1
P
2 1
P3
Then
1
P
V1 2 V2
P1
1
P V
V1 2 1
P1
P
2 1
P3
1
P2
P V
V1 1
V V1
1 1 1
P2 1
P P
1 1
P3 P3 P2
9.2.3 Sizing Accumulators for Emergency Reserve
This is a typical application where both isothermal and adiabatic conditions
prevail due to slow storage and quick discharge. For this condition, the
accumulator volume is given by
(i) Isothermal Charging
It can be shown that for isothermal conditions, the values of maximum gas
volume V1 at the precharge pressure P1 :
P .V Constant
P1 V1 P2 V2
P
V1 2 V2
P1
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(ii) Adiabatic Discharging
P V Constant
P2 V2 P3 V3
P2 V2 P3 V3
1
P
V3 2 V2
P3
V3 V2 V
1
P2
V2 V2 V
P3
1
P2
V2 1 V
P3
V
V2
1
P2
1
P3
Then
P
V1 2 V2
P1
P V P2 P1
V1 2 V1 V
P1 1 1
P2 P2
1 1
P3 P3
9.2.4 Sizing Accumulators for Pulsation Damping
Pulsation damping is typically an adiabatic condition because both
storage and discharge have to be accomplished in a very short time. Because
pressure pulsation is a phenomenon associated with piston pumps, the stored
volume V is a product of the pump displacement q in liters and a constant
k that depends on whether the pump is single-acting or double–acting and
the number of pistons involved. Pressure pulsation is highest in a single-
332
acting single–piston pump delivering large flows at high pressures. Here the
k factor is about 0.69 . A single–piston double–acting pump has the same k
factor as that of a double-piston single-acting pump whose k factor is equal
to 0.29 . A three or four–piston single– acting pump has a k factor of 0.12 .
For any other pump configuration, an average k factor of 0.05 can be taken
with reasonable accuracy.
The stored volume is given by:
V
V1 1 1
P1 P1
P2 P3
Where: V k .Q , where
L min
Q the pump flow rate in number of piston.
rpm
P2 P x and P3 P x
P1 0.7 P
P the average working pressure in bar
aP
x bar ,
100
a The percentage of pulsation.
9.2.6 Sizing of Additional Gas Bottles
Sometimes the size V1 as determined by the above equations may be
more than the available accumulator sizes or the size so determined is too big
for accommodation within the frame of the machine. Also sometimes it may
become necessary to maintain a small difference between P2 and P3 , which
results in a higher stored volume V and a much larger accumulator volume
V1 . In such cases, it is convenient to get required volume by additional
bottles.
For example, if an application requires 43 L of fluid to be discharged
adiabatically between 70 and 55 bar , the total volume required would be
close to 434 L . The volume requirement is high because the pressure
difference is small. If a 22.5 cm bore piston accumulator can hold 125 L , then
auxiliary gas bottles can be installed some distance away to meet the balance
of volume requirement.
333
In applications such as energy reserve volume compensation and
hydraulic line shock damping, it is recommended that a higher pre-charge
pressure P1 0.97 P2 be maintained. After obtaining the value of V1 in the
normal way, it must be split into two portions: The minimum indispensable
portion that is contained in the accumulator and the portion that is contained
in additional gas bottles.
9.3 Applications of Accumulators
There are five basic applications where accumulators are used in a hydraulic
system:
1. Accumulator as an auxiliary power source: The purpose of accumulator
in this application is to store the oil delivered by the pump during a portion of
the work cycle. The accumulator then releases the stored oil on demand to
complete the cycle, thereby serving as a secondary power source.
Fig. (9.8): Accumulator as an auxiliary power source
The schematic diagram is shown in Figure (9.8). When the four–way
valve is manually activated, oil flows from the accumulator to the blank end
of the cylinder. This extends the piston until it reaches the end of the stroke.
When the cylinder is in its fully extended position, the accumulator is being
charged. The four–way valve is then deactivated for retraction of the cylinder
oil flows from both the pump and accumulator to retract the cylinder rapidly.
2. Accumulator as a leakage compensator: An accumulator can be used as
a compensator for internal and external leakage during an extended period in
which the system is pressurized but not in operation. The pump charges the
accumulator and the system until the maximum pressure sets the pressure
switch ON. The schematic diagram is shown in Figure (9.9). The contacts on
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the pressure switch then open to automatically stop the electric motor that
drives the pump. The accumulator then supplies leakage oil to the system
during a long period. Finally, when the system pressure drops to the
minimum pressure setting of the pressure switch, it closes the electrical
circuit of the motor until the system gets recharged. The check valve is placed
between the pump and accumulator so that the pump does not reverse when
the motor is stopped and does not permit all the accumulator charge to drain
back into the power unit. With this circuit, the only time the power unit
operates is when the pressure drops to an unsafe operating level. This saves
electric power and reduces the heat in the system.
Fig. (9.9): Accumulator as a leakage compensator
[Link] as an emergency power source: In some hydraulic
systems, safety dictates that a cylinder be retracted even though the normal
supply of oil pressure is lost due to a pump or electrical power failures. The
schematic diagram is shown in Figure (9.10). In it, a solenoid activated three-
way valve is used along with the accumulator. When the three-way valve is
energized, oil flows to the blank end of the cylinder and also through the
check valve into the accumulator and the rod end of the cylinder. The
accumulator charges as the cylinder extends.
If the pump fails due to an electric failure, the solenoid de-energizes,
shifting the valve to its spring offset mode. Then the oil stored under pressure
is forced from the accumulator to the end of the cylinder. This retracts the
cylinder to its starting position.
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Fig. (9.10): Accumulator as an emergency power source
4. Accumulator as a hydraulic shock absorber: One of the important
applications of accumulators is the elimination of hydraulic shock. The
schematic diagram is shown in Figure (9.11). Hydraulic shock is caused by
the sudden stoppage or declaration of a hydraulic fluid flowing at relatively
high velocity in a pipe line. Rapidly closing a valve creates a compression
wave. This compression wave travels at the speed of sound upstream to the
end of the pipe and back again to the closed valve, which causes an increase
in pressure.
The resulting rapid pressure pulsations or high–pressure surges may
cause damage to the hydraulic system components. If an accumulation is
installed near the rapidly closing valve, the pressure pulsations or high–
pressure surges are suppressed.
336
Fig. (9.11): Accumulator as a hydraulic shock absorber
5. Accumulator as a thermal expansion compensator: When closed–loop
hydraulic systems are subjected to heat conditions, both the pipe lines and the
hydraulic fluid expand volumetrically. Because the coefficient of cubical
expansion of most fluids is higher than that for pipe material, this expanded
liquid volume increases the entire system pressure. This condition may cause
pressures to exceed the limits of safety and may damage the system
components. Under these conditions, an accumulator of proper capacity pre-
charged to the normal system working pressure is installed. It takes up any
increase in the system fluid volume, thus reducing the system pressure to its
safe limits. The accumulator also feeds the required volume into the system
as thermal contraction takes place. The schematic diagram of such an
arrangement is shown in Figure (9.12).
337
Fig. (9.12): Accumulator as a thermal expansion compensator
Example (9.1)
In a particular hydraulic system a discharge of 10 Liter is required during
6 seconds once every minute. Calculate the suitable size of accumulator if:
– Minimum system pressure P3 is 100 bar
– Maximum system pressure P2 is 150 bar
– Pre-charge P1 is 0.9 of the minimum system pressure.
– The gas is compressed isothermally during the charging
– The gas expands adiabatically during discharge.
Solution
P1 0.9 P3 0.9 100 90 bar gage
P1 90 1 91 bar
P3 100 1 101 bar
P2 150 1 151 bar
V Q p Qsystem
60 6
V 10 10 9 Liter
60 60
This is a case of isothermal compression and adiabatic expansion. The
equation considered here is :
338
P2 P1
V1 V
1
P2
1
P3
151 91
V1 1
9 44.88 Liter
151 1.4 1
101
Example (9.2)
An accumulator is charged for the first 20 s and discharged in 2 s . The
delivery expected from the accumulator is 0.6 L in 2 s as the pressure falls
from 250 bar to 140 bar . Calculate the accumulator volume. Assume the gas
is compressed isothermally during the charging and the gas expands
adiabatically during discharge.
Solution
P1 0.9 P3 0.9 140 126 bar gage
P1 126 1 127 bar
P3 140 1 141 bar
P2 250 1 251 bar
V 0.6 2 1.2 Liter
This is a case of isothermal compression and adiabatic expansion. The
equation considered here is:
P2 P1
V1 V
1
P2
1
P3
251 127
V1 1
1.2 4.65 Liter
251 1
1. 4
141
339
Example (9.3)
A hydraulic molding press is kept closed at a maximum system pressure of
200 bar for a duration of 60 min during the curing period. The maximum
leakage permitted during this period is 2 cm 3 min and minimum fall in
pressure permitted is 198 bar . Calculate the accumulator volume. Assume the
gas is compressed isothermally during the charging and the gas expands
isothermally during discharge.
Solution
P1 0.9 P3 0.9 198 178.2 bar gage
P1 178.2 1 179.2 bar
P3 198 1 199 bar
P2 200 1 201 bar
2
V 60 0.12 Liter
1000
This is an application where the accumulator is used as a leakage
compensator under isothermal conditions. Therefore, the equation used for
this is:
V
V1
P1 P1
P3 P2
0.12 0.12
V1 13.4 Liter
179.2 179.2 0.00896
199 201
Example (9.4)
A three–piston single–acting pump of flow rate Q 133 L min is operating at
20 bar and at 148 rpm . Calculate the accumulator volume needed to limit the
remaining pulsation to 2.5% . Take the constant k equal 0.12.
Solution
This is a typical condition of pulsation damping in adiabatic phase due to
high–speed compression and expansion. For this condition:
V
V1 1 1
P1 P1
P2 P3
340
L min
(1) Q The pump flow rate in number of piston.
rpm
133
Q 3 2.7
148
(2) V k .Q 0.12 2.7 0.324 L
a P 2.5 20
(3) x 0.5 bar
100 100
(4) P2 P x 20 0.5 19.5 bar
P3 P x 20 0.5 20.5 bar
P1 0.7 P 0.7 20 14 bar
Substituting these values into the above equation, we have:
V
V1 1 1
P1 P
1
P2 P3
0.324 0.14
V1 1 1
5.1 Liter
0.0277
14 1.4 14 1.4
19.5 20.5
Example (9.5)
A dead–load accumulator has a cylinder bore of 500 mm and is to operate at
a system pressure of 200 bar . What is the dead load required?
Solution
The dead load required will be the product of piston area times the pressure:
Fload P. A p
Fload P D2
4
2
Fload 200 10 5 0.5
4
Fload 39.3 10 5 N 3930 KN
Example (9.6)
Calculate the increase in pressure if a cylinder 300 mm diameter 500 mm
stroke is locked in the extended condition and then subjected to a 20 0 C rise
in temperature. What is the volume of fluid to be stored in an accumulator
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fitted to compensate for thermal expansion? (Take the bulk modulus to be
15000 bar ).
Solution
Total volume of fluid contained in the cylinder is:
Vcylinder D2L
4
2
Vcylinder 0.3 0.5 0.03534 m 3
4
Change in volume is:
V Vcylinder T
V 0.0007 0.03534 20 0.000485 m 3
which is the additional volume to be stored. Without an accumulator, the
change in pressure in the closed system is:
P
V
V
V 0.000485
P 15000 205.86 bar
V 0.03534
Example (9.7)
What size of accumulator is necessary to supply 500 c c of fluid in a
hydraulic system of maximum pressure of 200 bar that drops to 100 bar
minimum? Assuming gas pre–charged of 66 bar , find adiabatic and
isothermal solution.
Solution
P1 66 1 67 bar
P2 200 1 201 bar
P3 100 1 101 bar
V 500 cc 500 cm 3 0.5 Liter
(a) Isothermal charging and discharging
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V
V1
P1 P1
P3 P2
0.5 0.5
V1 1.515 Liter
67 67 0.33
101 201
(b) Adiabatic charging and discharging
V
V1
1 1
P1 P1
P3 P2
0.5 0.5
V1 1 1
1.726 Liter
0.28965
67 1.4 67 1.4
101 201
Example (9.8)
What size of accumulator is necessary to supply 4917 cm 3 of fluid into a
hydraulic system of maximum operating pressure of 207 bar that drops to
minimum 103.5 bar ? Assuming a nitrogen gas pre-charge of accumulator to
be 67 bar , obtain both isothermal and adiabatic solutions.
Solution
P1 67 1 68 bar
P2 207 1 208 bar
P3 103.5 1 104.5 bar
V 4917 cm 3 4.917 Liter
(a) Isothermal charging and discharging
V
V1
P1 P1
P3 P2
343
4.917 4.917
V1 15.18 Liter
68 68 0.323795
104.5 208
(b) Adiabatic charging and discharging
V
V1
1 1
P1 P1
P3 P2
4.917 4.917
V1 1 1
17.21 Liter
0.28575
68 1.4 68 1.4
104.5 208
Example (9.9)
A gas–charged accumulator supplies energy to a system with 15 L of oil
within the pressure range of 125 bar 175 bar . If the accumulator has pre–
charged pressure of 90 bar , size the accumulator for (a) isothermal and (b)
adiabatic pressures.
Solution
Stages of pre–charging, charging and discharging are shown.
P1 90 1 91 bar
P2 125 1 126 bar
P3 175 1 176 bar
V 15 Liter
(a) Isothermal charging and discharging
V
V1
P1 P1
P3 P2
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15 15
V1 73.11 Liter
91 91 0.205177
126 176
(b) Adiabatic charging and discharging
V
V1
1 1
P1 P1
P3 P2
15 15
V1 1 1
89.118 Liter
0.168316
91 1.4 91 1.4
126 176
Example (9.10)
An accumulator has a ram diameter of 0.4 m and lift of 10 m . It is loaded
with 1000 KN of total weight. The packing friction is 5% of the load on the
ram. Find the power delivered to the main if the RAM descends steadily
through its full stroke in 5 mm while the pump delivers 50 L s through the
accumulator.
Solution
The pressure developed in an accumulator due to weight is:
Net Load
Pressure
Area
Load - Friction
Pressure
Area
1000 - 0.05 1000
Pressure
2
D
4
950
Pressure 7560 kPa
2
0.4
4
Pressure energy (head) supplied by the accumulator to water is:
P 7560 10 3
h 770.6 m of water
.g 1000 9.81
Energy supplied by the accumulator (during ascend) g Q h
1000 9.81 50 10 3 770.6
377980 W
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Net Load Stroke
Energy supplied by the accumulator (during descend)
Time of Descent
950 10 3 10
31667 W
300
Total power delivered 377980 31667 409647 W 409.65 kW
Example (9.11)
A gas–charged accumulator supplies energy to a system with 6.7 L of oil in
5 second within the pressure range of 150 bar 110 bar . The accumulator
has the pre–charge pressure of 85 bar . What should be the size of the
accumulator if the oil is to be supplied (a) in about 5 second and (b) in about
5 min ? Assume the gas is compressed during the charging and expands
during discharge adiabatically and the specific heats ratio is 1.25 .
Solution
Stages of pre-charging, charging and delivery are shown in Figure:
P1 85 1 86 bar
P2 150 1 151 bar
P3 110 1 111 bar
6.7
V 1.34 L s
5
For Adiabatic charging and discharging
V
V1
1 1
P1 P1
P3 P2
1.34 1.34
V1 1 1
7.53 Liter s
0.17794
86
1.25 86
1.25
111 151
(a) The oil is to be supplied in about 5 seconds
Capacity of accumulator 7.53 5 37.65 Liter
(b) The oil is to be supplied in about 5 minutes
Capacity of accumulator 7.53 5 60 2259 Liter
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Example (9.12)
A circuit has been designed to crush a car body into bale using a 152 mm
diameter hydraulic cylinder. The hydraulic is to extend 2.54 m during a
period of 10 seconds . The time between crushing strokes is 5 min . The
following accumulator gas absolute pressures are given
Gas pre-charge pressure, P1 84 bar abs
Gas charge pressure when the pump is turned ON, P2 210 bar abs
Pressure relief value setting P2 210 bar ,
Minimum pressure required to actuate load, P3 126 bar abs
Assume the gas is compressed during the charging and expands during
discharge isothermally.
(a) Calculate the required size of the accumulator.
(b) What are the pump hydraulic kW power and flow requirements with and
without accumulator?
Solution
Stages of pre–charging, charging and delivery are shown in Figure below:
P1 84 bar
P2 210 bar
P3 126 bar
(a) Without accumulator
The compression and expansion of gas follow isothermal law:
P1V1 P2V2 P3V3
Here Vc is the volume of hydraulic cylinder. It can accommodate
V3 V2 amount of :
P2V2 P3V3
347
P2V2 210 V2
V3 1.667 V2
P3 126
Vc D 2 Lc 0.1522 2.54 0.0461 m 3 V3 V2
4 4
V3 V2 0.0461
1.667V2 V2 0.0461
0.667V2 0.0461 V2 0.06815 m 3
V3 0.11525 m 3
P1V1 P2V2
P2V2 210 0.06815
V1 0.17 m 3 170 Liter
P1 84
V Vc D 2 Lc 0.1522 2.54 0.0461 m 3
4 4
(b) With accumulator
The pump charges accumulator in every 2.5 min . In other words, two times
in five minutes.
Flow supplied by the pump:
2V3 V2 2 Vc 2 0.0461
Qp 0.000307 m 3 s 0.307 L s
5 60 300 300
Neglecting all losses, power supplied to the pump is:
Pp Q p
Pump Power
600 0
Prelief valve Q p
Pump Power
600 0
210 0.307 60
Pump Power 6.45 kW
600 1
Without accumulator
The pump extends cylinder in 10 second . Flow supplied by the pump is:
0.0461
Qp 0.00461 m 3 s 4.61 L s
10
Neglecting all losses, power supplied to the pump is:
Pp Q p
Pump Power
600 0
348
Poperating Q p
Pump Power
600 0
126 4.61 60
Pump Power 58.1 kW
600 1
It can be seen that flow and power requirement by the pump is more without
accumulator.
Example (9.13)
A pump/accumulator power pack is to supply the fluid flow demand by the
system as shown in figure. The system working pressure is 200 bar , the
maximum pressure at accumulator is 300 bar and the accumulator pre–charge
pressure is 90% of the working pressure. The charging and discharging
processes are considered isothermal and isentropic, respectively. Calculate:
(a) The actual pump delivery
(b) The maximum volume of fluid to be stored in the accumulator
(c)The accumulator volume
60
55
50
Discharge (L/min)
45
40
35
30
25
20
15
10
0
0 5 10 15 20 25 30
Time (sec)
Solution
(a) The actual pump delivery
Q p total time Q t system
Q p 30 45 5 10 7.5 60 5
30 Q p 600 Q p 20 L min
(b) The maximum volume of fluid to be stored in the accumulator
349
Time (s) Pump Flow (L) System Required Net Flow Accumulated
(L) (L) (L)
0–5 5 5 2.0833 2.0833
20 1.6667 45 3.75
60 60
5 – 10 5 0 1.6667 0.41666
20 1.6667
60
10 – 20 10 10 2.0833 1.6667
20 3.333 7.5 1.25
60 60
20 – 25 5 0 1.6667 3.333
20
1.6667
60
25 – 30 5 5 3.333 0
20 1.6667 60 5
60 60
Maximum volume stored V
V 3.3333 2.0833 5.4166 L
(c)The accumulator volume
V1
P2 P1 V
P2 P3 1 1
V1
301 181 5.4166 26.94 L
301 2011 1.4 1
Example (9.14)
A pump/accumulator power pack is to supply the fluid flow demand by the
system as shown in figure. The system working pressure is 125 bar , the
maximum pressure at accumulator is 200 bar and the accumulator pre–charge
pressure is 90% of the working pressure. The charging and discharging
processes are considered isothermal. Calculate:
(a) The actual pump delivers
(b)The maximum volume of fluid to be stored in the accumulator
(c) The accumulator volume
350
50
45
40
Discharge (L/min)
35
30
25
20
15
10
0
0 5 10 15 20 25 30
Time (sec)
Solution
(a) The actual pump delivers
Q p total time Q t system
Q p 30 45 5 30 5 15 5
30 Q p 450 Q p 15 L min
(b)The maximum volume of fluid to be stored in the accumulator
Time (s) Pump Flow System Required Net Flow Accumulated
(L) (L) (L) (L)
0–5 5 5 2 .5 2 .5
15 1.25 45 3.75
60 60
5 – 10 5 0 1.25 1.25
15 1.25
60
10 – 15 5 5 1.25 2 .5
15 1.25 30 2.5
60 60
15 – 25 10 0 2 .5 0
15 2.5
60
25 – 30 5 5 0 0
15 1.25 15 1.25
60 60
Maximum volume stored V
V 0 2.5 2.5 L
(c) The accumulator volume
351
V
V1
P1 P1
P3 P2
2.5
V1 7.44 L
113 .5 113 .5
126 201
Example (9.15)
The hydraulic system to be supplied by the pump and accumulator has a
circuit demand characteristic for flow and pressure as shown in figure. The
complete cycle time is 30 seconds. The maximum cycle pressure is
207 bar and the system working pressure is 150 bar . If the accumulator pre–
charge pressure is 90% of the maximum system pressure. Determine:
(a) The actual pump delivery
(b) The maximum flow accumulated in the accumulator
(c)The accumulator volume assuming the isothermal charge and isentropic
discharging
(d) The overall system efficiency
207 bar
To system
352
30 160
150
140
25
Load Induced Pressure (bar)
130
120
20 110
Flow (L/min)
100
90
15 80
70
60
10
50
40
5 30
20
10
0
0 5 10 15 20 25 30 0
0 5 10 15 20 25 30
Time (sec) Time (sec)
Solution
(a) The actual pump delivery
Q p total time Q t system
Q p 30 25 5 20 10
30 Q p 325 Q p 10.833 L min
(b) The maximum flow accumulated in the accumulator
Time (s) Pump Flow (L) System Required Net Flow Accumulated
(L) (L) (L)
0–5 5 0 0.90278 0.90278
10.833 0.90278
60
5 – 10 5 5 1.18052 0.27774
10.833 0.90278 25 2.0833
60 60
10 – 20 10 0 1.8055 1.5278
10.833 1.8055
60
20 – 30 10 10 1.5278 0
10.833 1.8055 20 3.3333
60 60
Maximum volume stored V
V 1.5278 0.27774 1.8055 L
(c) The accumulator volume
353
P2 P1
V1 1
V
P2 1
P3
208 151
V1 1
1.8055 31.9875 Liter
208 1
1.4
187.3
(d) The overall system efficiency
Q p Pp
Pump Power 30
600 0
10.833 150
Pump Power 30 81.2475 KJ
600
System Power Qsystem Psystem time
25 0.5 5 150 20 0.5 10 100
System Power 0 0
600 600
System Power 15.625 16.667 32.292 KJ
System Power
system
Pump Power
32.292
system 0.3975
81.2475
354
PROBLEMS
9.1 Calculate the increase in pressure if the cylinder 300 mm diameter and
500 mm stroke is locked in the extended condition and then subjected to
P
20OC temperature rise. Taking the bulk modulus 15000 bar and
V
V
the coefficient of volumetric expansion, 0.0007 . It is required to relief
the excess volume either by using accumulator or relief valve. Find the power
saving when the accumulator is used assuming the system working pressure
is 150 bar.
9.2 A hydraulic accumulator is installed to protect a hydraulic line against an
excessive rise in pressure due to thermal expansion. Derive an expression for
the proper size of this accumulator if the permissible pressure increment is
ΔP for a temperature increase of ΔT.
9.3 Calculate the size of a hydraulic accumulator necessary to deliver five
liters of oil between pressures of 200 and 100 bar if the charging pressure is
90 bar (gauge pressure), assuming an adiabatic compression process.
9.4 A hydraulic system operates in a regular operating cycle of 50 s duration.
The flow demand during the operating cycle is shown in the figure that
follows. The maximum pump delivery pressure during the operating cycle is
160 bar, and the flow rates are set by a flow control arrangement. The system
has a fixed displacement pump. Determine the required pump flow rate in the
following cases:
(a) When using the pump only for hydraulic power supply.
(b) If a hydraulic accumulator is used to compensate for the short duration
flow demands. Calculate the suitable size of the accumulator if the maximum
allowable pressure is 240 bar.
355
9.5 A pump/accumulator power pack is to supply the fluid flow demand by
the system as shown in figure. The system working pressure is 250 bars, the
maximum pressure at accumulator is 350 bars and the accumulator pre-
charge pressure is 90% of the working pressure. The charging and
discharging processes are considered isothermal and isentropic, respectively.
Calculate:
(a) The actual pump delivery
(b) The maximum volume of fluid to be stored in the accumulator
(c) The accumulator volume.
(d) The pump displacement volume, VD in mL/rev if it runs at 1750 rpm
(ηv=0.92)
(e) The pump displacement volume, VD in the case of no accumulator
(N=1750 rpm)
(f) The power required to derive the pump in two cases, when an accumulator
is used and without using accumulator. Assuming that the pump the overall
efficiency, ηO= 0.85 and 250 bar working pressure.
60
55
50
45
Discharge, L/min
40
35
30
25
20
15
10
5
0
0 5 10 15 20 25 30
Time, sec
9.6 A hydraulic power generator has the following operating parameters:
Pump flow rate Q p 0.4 L s
Maximum operating pressure Pmax 70 bar
Minimum operating pressure Pmin 60 bar
Pump total efficiency 0 0.9
356
There is a demand for 0.8 Liter of oil over a period of t1 0.1 seconds , at
intermittent intervals. The minimum time interval between two successive
demands is t 2 30 seconds . Calculate the size of the suitable accumulator
and the maximum required power when operating with and without the
accumulator.
9.7 Fill in the Blanks
1. A hydraulic accumulator is a device that stores the potential energy of
an -----------------------held under pressure by an external source
against some dynamic force.
2. The main disadvantage of a weight-loaded or gravity accumulator is its
extremely -------------------------size and-----------------weight.
3. A spring–loaded accumulator stores energy in the form of a -------------
------spring.
4. Pulsation damping is typically an --------------------condition because
both storage and discharge have to be accomplished in a very short
time.
5. The nitrogen pre-charge pressure in an accumulator is based on the
expected maximum rise in the circulating hydraulic oil ------------------
-----
6. An accumulator permits-----------------------to be absorbed and stored in
a hydraulic system.
7. Air or -----------------------------should never be used in gas-charged
accumulators.
9.8 State True or False
1. A gas-loaded accumulator is popularly used in industries.
2. In a bladder accumulator, the bladder is filled with oxygen until the
designed pre–charge pressure is achieved.
3. An accumulator can be used as a compensator for both internal and
external leakages.
4. One of the important applications of accumulators is the elimination of
hydraulic shock.
5. An accumulator can be used as a fail–safe device.
9.9 Review Questions
1. Define an accumulator and explain its function.
2. What are the different types of accumulators?
357
3. Mention some of the industrial applications of an accumulator. Explain
any one of them with an example.
4. Why are accumulators used?
5. Define and derive an expression for the volumetric capacity of bladder-
type accumulators.
6. Explain the construction and operation of piston-type accumulators.
7. Explain the construction and operation of bladder-type accumulators.
8. Explain the construction and operation of diaphragm-type
accumulators.
9. Discuss in detail the application of hydraulic accumulators as energy
storage elements. Draw a hydraulic circuit for this application.
10. Discuss in detail the application of hydraulic accumulators for
protection against shocks.
11. Discuss in detail the application of hydraulic accumulators in
protecting against thermal expansion.
12. Discuss in detail the application of hydraulic accumulators for internal
leakage compensation and the application of constant pressure.
13 What is the difference between separator and non-separator types of
accumulators?
14 Name three different types of separator-type accumulators.
15. What are the advantages of bladder accumulators over piston
accumulators?
358