EXPT NO.

2 DATE:
PRESSURE CONTROL VALVES
AIM: To study Pressure control valves and circuits using Pressure Control Valves.

INTRODUCTION:

Pressure control valves are those which control the force obtained by the actuator. They
perform different functions as:
1. Limiting maximum system pressure.
2. Regulating pressure in the system.
3. Controlling or checking pressure in operation is based on balance between pressure and
spring force.

Most of the pressure control valves are infinite positioning i.e. valves can assume various
positions between fully closed and fully opened.

THEORY:
Various types of Pressure Control Valves are:

1. Pressure relief valve

2. Pressure reducing valve
3. Unloading Valve
4. Sequence valve
5. Counter balance valve
6. Brake valve

1. Simple Relief Valve:

It is also called as direct acting relief valve. Its purpose is to limit the pressure in the system by
directing some or all of the pumps o/p to tank when presetting is reached.

Simple relief valve consisting of adjusting of screw, a spring with two support plates at top and
bottom and a conical poppet sealed inside the valve casing. The spring force is adjusted to a
specific value by means of adjusting screw. The inlet port is connected to pressure line, while
the outlet port to the reservoir. When the pressure at inlet is insufficient to overcome the spring
force, poppet remains seated, thus valve remain closed, fig. ( ). As soon as inlet pressure is
greater than spring force, poppet is lifted up from seat and fluid flows to the reservoir, fig ( ).
The pressure at which the relief valve opens can be adjusted by changing the amount of spring
compression, which changes the force applied to the ball on spring side. This type of relief valve
is called direct acting since the ball is directly exposed to the pump pressure.

 Cracking Pressure:

The pressure at which the valve begins to direct the flow is called as cracking pressure.
 Full Flow Pressure:

The pressure at the inlet when valve is passing its volume is called full flow pressure.

 PILOT OPERATED RELIEF VALVE:

It is also called as balance piston relief valve. Pilot stage in upper body contains pressure
limiting valve. A poppet held against a seat by a light spring and balanced piston is placed in
lower body where port connections are made.

The balanced piston is in hydraulic balanced i.e. pressure in upper and lower chamber is equal
at any pressure less than the valve setting and orifice maintain pressure equal when it reaches
the setting, the poppet the forced off its seat limiting pressure in lower chamber is increased.

As flow through orifice is restricted so that the pressure in lower chamber is increased, creating
a hydraulic unbalance between upper and lower chamber. When the difference of pressure
overcomes the spring pressure above the piston, it moves upwards opening the passage to
outlet port, further increasing the flow through the valve. These types of valves are usually
smaller than the direct operated PRV’s for same flow and pressure ratings. They also have wide
range for maximum pressure setting.

 GRAPH:

If the pump flow is going through a tandem neutral back to the tank, the pressure will be very
low because the resistance to flow is very low. If the pump flow is forced to go to a loaded
cylinder, the pressure will be proportional to load. Thus, pressure relief valves do not control the
pressure level in a circuit at all times. Rather they control the maximum pressure in a circuit by
providing an alternate flow path for the fluid when the pressure reaches the relief setting.

The crossover pressure relief valve is a variant of the pressure relief valve. These valves are
used to prevent shifting shock in motor circuits. Shifting shock can occur in hydraulic motor
circuits when a directional control valve is shifted in to the closed position. If the motor has a
large amount of momentum built up, shifting the valve closed can cause a large pressure spike
on the outlet line because the motor tends to keep spinning and will therefore try to push the
fluid to its outlet.

2. Unloading Valves:

The function of an unloading valve is to unload the pressure at the desired instant in order to
conserve the bores power and protection to system. These valves are remotely operated.

An external pressure is to move the spool and direct pump delivery to through secondary port.
The drain connection remains internal, since the secondary port is still connected to the tank. In
case of unloading valve, the primary port pressure is independent of the spring force because
the remote source operates the spool.

3. Unloading Valve Circuit:

When the pressure is below the 1000psi, flow is supplied to the cylinder from both sides. When
pressure reaches 1000 psi, the unloading valve opens and unloads the high flow pump back to
tank at low pressure. Only low flow pump supplies the cylinder with flow at pressures from 1000
psi to 3500 psi. If the pressure reaches 3500 psi, flow from the low flow pump is forced over the
relief valve at this pressure. Check valve 1 isolates the high flow pump from the system
pressure while it is being unloaded. Check valve 2 prevents the flow from the high flow pump
from flowing into the low flow pump line. This would reverse the low flow pump, which would
cause damage to the power unit.

4. Sequence Valves:

A sequence valve is used to cause actions to take place in a system in definite order, and to
maintain a predetermined minimum pressure in the primary line while secondary operation
occurs. This valve uses a spring loaded spool to control down system pressure.
If the main supply pressure is below the valve setting, fluid flows freely from inlet to outlet
pressure to the spool and opposite to spring. When the outlet pressure rises to the valve setting,
the spool moves to partly block the port. Only enough flow is allowed to pass to outlet to
maintain preset pressure. If the valve closes completely leakage past the spool could cause the
pressure to build up. Instead a continuous bleed to the tank is provided to keep it slightly open
and prevent down stream pressure from rising above the valve setting.

To maintain pressure in the primary system, the valve is internally operated. However the drain
connection must be external, since the secondary port is under pressure. If this pressure were
allowed in the drain passage it adds to the spring force and raises the pressure required to open
the valve.

5. Pressure Reducing Valves:

Pressure reducing valves are normally-open pressure controls used to maintain reduced
pressures in certain portions of the system. They are actuated by pressure sensed in the branch
circuit and tend to close as it reaches the valve setting, thus preventing the further buildup.

6. Direct Acting Pressure Relief Valve:-

In this, the line requiring backpressure is connected to the primary port and the secondary port
is connected to tank. The application permits the valve to be internally drained and the drain
passage is compelled from the primary port making it necessary to maintain adequate back
pressure to keep the valve open. It uses a spring loaded spool to control the downstream
pressure.

If the main supply pressure is below the valve setting, fluid will flow freely from inlet to outlet.
When outlet pressure rises to the valve setting, the spool moves to partly block the outlet port.
Only enough flow is passed to the outlet to maintain the preset pressure. If the valve closes
completely, leakage past the spool could cause pressure to build up in the branch circuit.

 PILOT OPERATED PRESSURE REDUCING VALVE:-

These are normally open pressure control valve used to maintain reduced spool orifice and pilot
valve to drain. The operating pressure is set by an adjustable spring in the pilot stage in the
upper body. The valve spool in the lower body functions in essentially the same manner as the
direct acting valve. The spool is hydraulically balanced through an orifice in its center, and the
light spring holds it in wide open position.

1. Counter Balance Valve:

It is referred as a foot valve. It is used to support weight or prevent uncontrolled load drop. It is
installed in outlet line .The counter balance valve serves as a hydraulic resistance to a cylinder
or a motor. In vertical application it is set to open at a pressure slightly higher than that
generated by the load. Thus an additional force is required to cause the valve to open and
permit the load to be lowered. Counter weights can be required where leakage of fluid past the
cylinder seals or valves spool would permit gradual setting over a extended period of time.

When the pump delivery is directed to the top of the cylinder, the cylinder piston is forced down
causing pressure at the primary port to increase and raise the spool, opening the flow path for
discharge through the secondary port to the directional valve and subsequently to the tank.

2. Brake Valve:

It is used in the exhaust line of a hydraulic motor to,

 Prevent over speeding when an over running load is applied to motor shaft.
 Prevent excessive pressure building up when decelerating or stopping the load.

When the valve is used as a brake it as a solid spool and there is remote operating pressure
connection in the bottom cover. This connection is fed into the line to the motor. The internal
connection is also used under the small piston and senses pressure from the primary port of the
valve which is connected to the motor exhaust port.

3. Accelerating:

When the load being accelerated, pressure is maximum at the motor inlet and under the large
area of the brake spool holding it in full open position, permitting free flow from the exhaust port
of the motor.

4. Running:

When the motor gets up to the speed, load pressure still holds the brake valve open unless the
load tries to run away. If this happens the pressure falls off at the motor inlet and in the remote
control pressure passage. The spring force tends to close the valve thus increasing the back
pressure. This in turn raises the drive line pressure to the motor and under the small piston
holding the valve at the proper metering position to maintain constant motor speed.

5. Braking:
When the directional valve is shifted to neutral, inertia causes the motor to continuous rotating.
It operates as a pump drawing fluid from reservoir and circulating back through the brake valve.
At this time pressure at motor outlet tending to bring it to stop will be whatever is required under
the small piston to overcome the brake valve setting.

 Brake Valve Circuit :

When the weight is lowered, it may tend to drive the motor, instead of the motor lowering the
weight. This is known as an overrunning load. In this situation, the load will probably accelerate
too quickly. The motor is being driven by the load and is basically acting as a pump. When this
occurs, the pressure at the outlet will be higher than the pressure at the inlet. The brake valve
senses the pressure in both the inlet and outlet lines of the motor, just as it is with the pump.
Whenever the pressure at the outlet is lower than the pressure at the inlet, the motor is
functioning normally and the brake valve allows nearly unrestricted flow out of the motor. When
the pressure at the outlet is higher than at the inlet, however, the brake valve closes partially to
provide enough of a back pressure on the outlet of the motor to keep the load in control. The
check valve allows the valve to be bypassed when the weight is being raised

EXERCISE

Enlist the applications of different types of pressure control valves.