M10 Installing and Maintian

Mechanics
Level-II
Based on March 2022, Curriculum Version 1
Module Title: - Installing and Maintaining Fluid Power Pipes and Tubes
Module code: IND MCS2 M10 0322
Nominal duration: 60 Hour
Prepared by: Ministry of Labor and Skill

August, 2022
Addis Ababa, Ethiopia
Page 1 of 97 Ministry of Labor and Installing and Maintaining Fluid Power Version -1
Skills Pipes and Tubes August, 2022
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Table of content
Acknowledgme nt ........................................................................................................................... 4
List of Table ................................................................................................................................... 5
List of Figures................................................................................................................................ 5
Introduction to the Module .......................................................................................................... 7
Unit one: Fluid Work plan requirement................................................................................... 8

1.1 apply work instructions ................................................................................................... 9
1.1.2 Types of Fluid Power System ............................................................................. 10
1.1.3Advantages of a Fluid Power System .................................................................. 10
1.1.4Applications of Fluid Power: ............................................................................... 10
1.2 OHS standards ............................................................................................................... 11
1.2.1 Fluid Power Hazards ........................................................................................... 11
1.2.2 Color Coding for Safety ...................................................................................... 12
1.3 Type of components, tools and equipment .................................................................... 15
1.3.1 Basic Components of a Hydraulic System .......................................................... 16
1.3.2 Basic Components of a Pneumatic System ......................................................... 17
Self-Check -1................................................................................................................................ 20
LAP Test ...................................................................................................................................... 22
Unit Two: Prepare and set-up work......................................................................................... 23

2.1. Identify Faults............................................................................................................... 24
2.2 Methods of Repairing Fault ........................................................................................... 24
2.3 Types of pipes and fittings ............................................................................................ 29
2.3.1 Types of Tubing, Piping, and Hose..................................................................... 29
2.3.2 Type of fittings .................................................................................................... 34
2.3.3 Sealing Devices and Materials ............................................................................ 36
2.4 Tools and equipment ..................................................................................................... 38
2.5 Circuit functions and components ................................................................................. 40
2.5.1 Basic fluid power component symbols ............................................................... 40
2.5.2 Basic Circuit diagram .......................................................................................... 50
Self cheek-2 .................................................................................................................................. 52
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Ope ration 1 .................................................................................................................................. 53
LAP Test 2 ................................................................................................................................... 54
Unit Three: Install fluid powe r pipes and tubes ...................................................................... 55

3.1 place Pipes in position ................................................................................................... 56
3.1.1 Sizing of Pipes..................................................................................................... 56
3.2 Install and Join Pipe system .......................................................................................... 58
3.2.1 Installing Pipe and hose....................................................................................... 58
3.2.2 Joining Pipes ....................................................................................................... 71
3.4 Conduct Repair .............................................................................................................. 75
3.4.1Repairing copper tube .......................................................................................... 75
3.4.2 Repairing Hose .................................................................................................... 77
Self-Check -3................................................................................................................................ 80
Ope ration 1 .................................................................................................................................. 81
Ope ration 2 .................................................................................................................................. 82
LAP test 1..................................................................................................................................... 83
Unit Four: Assure quality and cleanup work .......................................................................... 84

4.1Flushing and pressure testing components ..................................................................... 85
4.2.1. Flushing .............................................................................................................. 85
4.2.3 Pressure testing components ............................................................................... 86
4.2 Completing Test reports ................................................................................................ 92
4.3 Cleanup Work area, tools materials and equipment’s............................................ 93
4.3.1 Cleaning work area.............................................................................................. 93
Self cheek -4 ................................................................................................................................. 95
List of reference........................................................................................................................... 96
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Acknowledgment
Ministry of Labor and Skills wish to extend thanks and appreciation to the many
representatives of TVET instructors and respective industry experts who donated their time
and expertise to the development of this Teaching, Training and Learning Materials (TTLM).
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List of Table
Table 2 Warning Colors .............................................................................................................. 13
Table 3Comparison between a hydraulic and a pneumatic system</table> ...................................... 19
Table 4 types of pipe fitting ......................................................................................................... 35
Table 5 standard pipe size ........................................................................................................... 56
Table 6 tubing size designation .................................................................................................... 57
Table 7 typess joining ................................................................................................................. 71
List of Figures
Figure 1Principle of fluid work .................................................................................................... 10
Figure 2 disconnecting the case drain line..................................................................................... 12
Figure 3 Arrow in the picture is showing drain valve.................................................................... 15
Figure 4 the arrow in the picture is showing minims’ point ............................................................ 15
Figure 5 basic components hydraulic system ................................................................................ 16
Figure 6basic components of pneumatics...................................................................................... 17
Figure 7 Medium pressure synthetic rubber hose........................................................................... 31
Figure 8 Synthetic rubber hose identification. ............................................................................... 32
Figure 9 gasket and packing ........................................................................................................ 37
Figure 10 Dynamic seal .............................................................................................................. 38
Figure 11 compression of gasket.................................................................................................. 38
Figure 12Bender tools ................................................................................................................. 39
Figure 13Flange tool ................................................................................................................... 39
Figure 14Pipe wrench and cutter.................................................................................................. 39
Figure 15 testing hose ................................................................................................................. 60
Figure 16 effects of incorrect line size .......................................................................................... 61
Figure 17 bending technique........................................................................................................ 63
Figure 18 double Bending technique ........................................................................................... 64
Figure 19 Tube cutter.................................................................................................................. 69
Figure 20 Tube cutter.................................................................................................................. 69
Figure 21 Chip less cutter. ........................................................................................................... 70
Figure 23 Flaring tool. ................................................................................................................ 72
Figure 24 Correct and incorrect methods of installing flared fittings. .............................................. 74
Figure 25 Cut out the damaged section ......................................................................................... 76
Figure 26 Slip bender Figure 27 measuring ............................................................................ 76
Figure 28 Correct and incorrect methods of installing tubing ......................................................... 79
Figure 29 pressure switch ............................................................................................................ 91
Figure 30 Electro hydraulic pressure switch.................................................................................. 91
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Acronym
PPE – Personal Protective Equipment
RPE- Respiratory Protective Equipment
OD- outside diameter
ID-Inside Diameter
P - Lode
mm- milometer
Nm- Newton Meter
HP- hour’s power
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Introduction to the Module
In Mechanics filed; Installing and Maintaining Fluid Powe r Pipes and Tubes helps to
know the pipes and tubes installation, maintenance and repair to pumps, equipment and
machineries.
This module is designed to meet the industry requirement under the mechanics occupational
standard, particularly for the unit of competency: Installing and Maintaining Fluid Powe r
Pipes and Tubes.
This module covers the units :

 Fluid Work plan requirement
 set-up work
 Install fluid power pipes and tubes
 cleanup work
Learning Objective of the Module
 Apply fluid work techniques
 Set up work
 Perform pipes and tubes Installation
 Clean work
Module Instruction
For effective use this modules trainees are expected to follow the following module
instruction:
1. Read the information written in each unit
2. Accomplish the Self-checks at the end of each unit
3. Perform Operation Sheets which were provided at the end of units
4. Do the “LAP test” giver at the end of each unit and
5. Read the identified reference book for Examples and exercise
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Unit one: Fluid Work plan requirement
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 apply work instructions
 apply OHS standards
 Type of components, tools and equipment
This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Apply OHS standards
 Identify types of components, tools and equipment
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1. Fluid Work Plan Requirement
1.1 apply work instructions
Introduction
In the industry we use three methods for transmitting power from one point to another.
Mechanical transmission is through shafts, gears, chains, belts, etc. Electrical transmission is
through wires, transformers, etc. Fluid power is through liquids or gas in a confined space.
Fluid power is the technology that deals with the generation, control and transmission of
forces and movement of mechanical element or system with the use of pressurized fluids in a
confined system. Both liquids and gases are considered fluids. Fluid power system includes a
hydraulic system (hydra meaning water in Greek) and a pneumatic system (pneuma meaning
air in Greek). Oil hydraulic employs pressurized liquid petroleum oils and synthetic oils, and
pneumatic employs compressed air that is released to the atmosphere after performing the
work.
By the term “fluid” refer to air or oil, for it has been shown that water has certain drawbacks
in the transmission of hydraulic power in machine operation and control. Commercially, pure
water contains various chemicals (some deliberately included) and also foreign matter, and
unless special precautions are taken when it is used, it is nearly impossible to maintain valves
and working surfaces in satisfactory condition. In the cases where the hydraulic system is
closed (i.e., the one with a self-contained unit that serves one machine or one small group of
machines), oil is commonly used, thus providing, in addition to power transmission, benefits
of lubrication not afforded by water as well as inc reased life and efficiency of packing and
valves.
The application of fluid power is limited only by the ingenuity of the designer, production
engineer or plant engineer. If the application pertains to lifting, pushing, pulling, clamping,
tilting, forcing, pressing or any other straight line (and many rotary) motions, it is possible
that fluid power will meet the requirement.
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1.1.2 Types of Fluid Power System
Fluid power systems perform work by a pressurized fluid bearing directly on a piston in a
cylinder or in a fluid motor. A fluid cylinder produces a force resulting in linear motion,
whereas a fluid motor produces torque resulting in rotary motion.
Figure 1Principle of fluid work
The Fluid power system is divided in to two types. They are hydraulic and pneumatic
system depends upon the fluid medium used to transmit force. The hydraulic fluid power
system employ liquid (like as water, petroleum, oils and synthetic oils) as fluid medium. The
pneumatic fluid power system employs gas (Compressed Air) as the fluid medium
1.1.3Advantages of a Fluid Power System
A. Fluid power systems are simple, easy to operate and can be controlled accurately:
B. Multiplication and variation of forces: s of tons.
C. Multifunction control:
D. Low-speed torque:
E. Constant force or torque:
F. Low weight to power ratio:. .
G. Low-speed torque:
H. Constant force or torque:

1.1.4Applications of Fluid Powe r:
1. Agriculture: Tractors and farm equipments like ploughs, movers, chemical sprayers,
fertilizer spreaders.
2. Aviation: Fluid power equipments like landing wheels on airplane and helicopter,
aircraft trolleys, aircraft engine test beds.
3. Building Industry: For metering and mixing of concrete ingredients from hopper.
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4. Construction Equipment: Earthmoving equipments like excavators, bucket loaders,
dozers, crawlers, and road graders.
5. Defense: Missile- launch systems and Navigation controls
6. Fabrication Industry: Hand tools like pneumatic drills, grinders, bores, riveting
machines, nut runners
7. Food and Beverage: All types of food processing equipment, wrapping, bottling
8. Foundry: Full and semi-automatic molding machines, tilting of furnaces, die casting
machines
9. Material Handling: Jacks, Hosts, Cranes, Forklift, Conveyor system.
1.2 OHS standards

Employers have duties concerning the provision and use of personal protective equipment
(PPE) at work. PPE is equipment that will protect the user against health or safety risks at
work. It can include items such as safety helmets, gloves, eye protection, high- visibility
clothing, safety footwear and safety harnesses. It also includes respiratory protective
equipment (RPE).
1.2.1 Fluid Powe r Hazards
Hydraulic equipments and systems are designed to accomplish work using confined liquid
pressure to produce a greater mechanical force. The operators/ maintenance crews are
subjected to hazards from high pressure liquids and large mechanical forces. Fluid power
machine systems store fluid under high pressure. The workmen are exposed to following
hazards:
 burns from hot, high-pressure fluid

 Injection of fluid into the skin
 Fire Hazards
 bruises, cuts or abrasions from flailing hydraulic lines
 Injury of people due to unexpected movement of equipment.
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Figure 2 disconnecting the case drain line
Note: - leakage is testing procedure by improperly disconnecting the case drain line and holding it in
an open receptacle.
1.2.2 Color Coding for Safety
Color warnings mark physical hazards, indicate the location of safety equipment, and identify
fire and other protective equipment.
The MIL-STD-101 establishes the color code used to identify piping carrying hazardous
fluids. It applies to all piping installations in naval ind ustrial plants and shore stations where
color coding is used.
Five classes of materials have been selected to represent the general hazards for all dangerous
materials, while a sixth class has been reserved for fire protection materials. A standard color
represents each of these classes, as shown in Table 2. In some instances, piping systems that
do not require warning colors may be painted to match surroundings; in other instances, such
systems may be painted aluminum or black or remain unpainted.
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Table 1 Warning Colors
Class Standard Identification Class of Material

Color Marking
A Yellow FLAM FLAMMABLE MATERIALS. All materials known ordinarily
as flammables or combustibles. Of the chromatic colors,
yellow has the highest coefficient of reflection under white
light and can be recognized under the poorest conditions of
illumination.
B Brown TOXIC TOXIC AND POISONOUS MATERIALS. All materials
extremely hazardous to life or health under normal conditions
as toxics or poisons.
C Blue AAHM ANESTHETICS AND HARMFUL MATERIALS. All
materials productive of anesthetic vapors and all liquid
chemicals and compounds hazardous to life and property but
not normally productive of dangerous quantities of fumes or
vapors.
D Green OXYM OXIDIZING MATERIALS. All materials which readily
furnish oxygen for combustion, and fire producers which
react explosively or with the evolution of heat in contact with
many other materials.
E Gray PHDAN PHYSICALLY DANGEROUS MATERIALS . All materials
not dangerous in themselves, but which are asphyxiating in
confined areas or which are generally handled in a dangerous
physical state of pressure or temperature.
F Red FPM FIRE PROTECTION MATERIALS. Materials provided in
piping systems or in compressed gas cylinders for use in fire
protection.
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General safety precautions during maintenance of fluid powe r machine System
Positive isolation procedure to be followed before start of any fluid power machine
 Depressurize the system before start of work. Shut down/ Local Isolation may be
taken, if required.
 Never begin work on a hydraulic system until fully trained.
 Never begin work on a hydraulic system without using a risk assessment.
 Carefully review the manuals on equipments before beginning work. Ask questions
about anything you do not fully understand.
 Read the Material Safety Data Sheet (MSDS) for chemicals used.
 Use all required safety Equipments.
 Never try to repair a part without having full knowledge about it.
 Each hydraulic system must have a documented procedure of de-energizing and load
locking. This should be known to all maintenance personnel.
 Document and practice de-pressurizing procedure in each of the circuit.
 While testing the system after repair never stand close to the unit. Any component,
pipe, hose, fitting may fail.
 Before start of work, drain the pressure line through minimesh point upto the
actuator.
 Drain the accumulator, if any, from drain valve and check oil pressure from minimess
coupling provided in safety block or main pressure line after accumulator. (Refer Fig.-
3 and Fig.– 4). If pressure gauge is showing zero, then also bleed the accumulator
with minimess hose for confirmation.
 During the tightening of pressurized lines hammering should not be done.
 Tightening of Joints should be done in depressurized condition.
 In any of the hydraulic maintenance jobs, all other agencies working in that area
should be well communicated about the hydraulic work and its effects.
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Figure 3 Arrow in the picture is showing drain valve
Figure 4 the arrow in the picture is showing minims’ point
1.3 Type of components, tools and equipment

Fluid power is called hydraulics when the fluid is a liquid and is called pneumatics when the
fluid is a gas. Hydraulic systems use liquids such as petroleum oils, synthetic oils, and water.
Pneumatic systems use air as the gas medium because air is very abundant and can be readily
exhausted into the atmosphere after completing its assigned task.
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1.3.1 Basic Components of a Hydraulic System
Hydraulic systems are power-transmitting assemblies employing pressurized liquid as a fluid
for transmitting energy from an energy- generating source to an energy- using point to
accomplish useful work. There are six basic components required in a hydraulic system:
1) Tank (reservoir) to hold the hydraulic oil.
2) Pump to force the oil through the system.
3) An electric motor or other power source to drive the pump.
4) Valves to control oil direction, pressure, and flow rate.
5) An actuator to convert the pressure of the oil into mechanical force to do the useful work.
6) Piping to carry the oil from one location to the other.
Figure 5 basic components hydraulic system
Pressure regulator
Functions of the components shown in Fig. 6 are as follows:
1. The hydraulic actuator is a device used to convert the fluid power into mechanical power
to do useful work. The actuator may be of the linear type (e.g., hydraulic cylinder) or rotary
type(e.g., hydraulic motor) to provide linear or rotary motion, respectively.
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2. The hydraulic pump is used to force the fluid from the reservoir to rest of the hydraulic
circuit by converting mechanical energy into hydraulic energy.
3. Valves are used to control the direction, pressure and flow rate of a fluid flowing through
the circuit.
4. External power supply (motor) is required to drive the pump.
5. Reservoir is used to hold the hydraulic liquid, usually hydraulic oil.
6. Piping system carries the hydraulic oil from one place to another.
7. Filters are used to remove any foreign particles so as keep the fluid system clean and
efficient, as well as avoid damage to the actuator and valves.
8. Pressure regulator regulates (i.e., maintains) the required level of pressure in the hydraulic
fluid.
1.3.2 Basic Components of a Pneumatic System
A pneumatic system carries power by employing compressed gas, generally air, as a fluid for
transmitting energy from an energy-generating source to an energy-using point to accomplish
useful work. Figure 1.3 shows a simple circuit of a pneumatic system with basic components.
Figure 6basic components of pneumatics
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The functions of various components shown in Fig. 7 are as follows:
1. The pneumatic actuator converts the fluid power into mechanical power to perform
useful work.
2. The compressor is used to compress the fresh air drawn from the atmosphere.
3. The storage reservoir is used to store a given volume of compressed air.
4. The valves are used to control the direction, flow rate and pressure of compressed a ir.
5. External power supply (motor) is used to drive the compressor.
6. The piping system carries the pressurized air from one location to another.
7. Air is drawn from the atmosphere through an air filter and raised to required pressure
by an air compressor.
As the pressure rises, the temperature also rises; hence, an air cooler is provided to cool the
air with some preliminary treatment to remove the moisture. The treated pressurized air then
needs to get stored to maintain the pressure. With the storage reservoir, a pressure switch is
fitted to start and stop the electric motor when pressure falls and reaches the required level,
respectively.
The three-position change over the valve delivering air to the cylinder operates in a way
similar to its hydraulic circuit.
Comparison between Hydraulic and Pneumatic Systems
Usually hydraulic and pneumatic systems and equipment do not compete. They are so
dissimilar that there are few problems in selecting any of them that cannot be readily
resolved. Certainly, availability is one of the important factors of selection but this may be
outweighed by other factors. In numerous instances, for example, air is preferred to meet
certain unalterable conditions, that is, in “hot spots” where there is an open furnace or other
potential ignition hazard or in operations where motion is required at extremely high speeds.
It is often found more efficient to use a combined circuit in which oil is used in one part and
air in another on the same machine or process.
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Table 2Comparison between a hydraulic and a pneumatic system</table>
Hydraulic System Pneumatic System
1 It employs a pressurized liquid as a fluid It employs a compressed gas, usually air,

as a fluid
2 An oil hydraulic system operates at A pneumatic system usually operates
pressures up to 700 bar at 5–10 bar
3 Generally designed as closed system Usually designed as open system
4 The system slows down when leakage Leakage does not affect the system
occurs much
5 Valve operations are difficult Valve operations are easy
6 Heavier in weight Lighter in weight
7 Pumps are used to provide pressurized Compressors are used to provide
liquids compressed gases
8 The system is unsafe to fire hazards The system is free from fire hazards
9 Automatic lubrication is provided Special arrangements for lubrication
are needed
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Written Test
Self-Check -1
PART-I: Write “TRUE” if the statement is correct and “FALSE” if it is wrong

statement.
1. Hydraulic power is especially useful when performing heavy work.

2. Water is a good functional hydraulic fluid
3. Pneumatic system is not free from fire hazards.
4. Pneumatic System Pumps are used to provide pressurized liquids
5. hydraulic system operates at pressures up to 5-10 bar
PART-II: Select the best answer from the given alternatives and write its
letter on the space provided
1. a type of component used for remove any foreign particles
A. Reservoir B. Filters hydraulic C. pump D. Valves
2. A type of component is used to control the direction, pressure and flow rate of a fluid
flowing through the circuit.
A, hydraulic actuator B. hydraulic pump C. Valves D. motor
3. One of the following is in correct about Hydraulic System
A. It employs a pressurized liquid as a fluid
B. The system slows down when leakage occurs
C. Carry Heavier weight compare to pneumatic
D. Compressors are used to provide compressed oil
4. Which one of the following is not correct about fluid power safety
A. Depressurize the system before C. try to repair a part without having
start of work full knowledge about it
B. Tightening of Joints should be D. None
done in depressurized condition
5. a type of component used for hold the hydraulic liquid, usually hydraulic oil
A. Reservoir B. Hydraulic actuator C. hydraulic pump D, Valves
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PART-III: Match the items listed under column “A” with those expressions listed under
“B”
“Column A” “Column B”
_____1. Carry the fluid from one location to the other A. hydraulic actuator
_____2. Fresh air drawn from the atmosphere B Pressure regulator
_____3.Component of pneumatic fluid power system C Compressor

_____4componet of hydraulic fluid power system D piping system
_____ 5.device used to convert the fluid power into mechanical E. pump
PART IV Sort answe r
1. List three methods for transmitting power from one point to another
2. Mention Classification of Fluid Power Systems
3. List at list 5 Advantages of a Fluid Power System
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Practical Demonstration
LAP Test
Task 1: Identify hydraulic and pneumatic component from the given diagram.
Task 2: Describe the function of fluid power components. from the given diagram.
Task 3 much the given drawing (diagram)
Diagram
1. Select from the table and Fill the name of the hydraulic component on the given blank
space
1. pressure regulator 3. Filter, 5. motor, 7. pump,
2. directional control valve 4. oil tank 6. actuator 8. Load
1. Select from the table and Fill the name of the pneumatic component system on the
given blank space
1 Air compressor 2. Filter, 3. motor, 4. Air actuator
5.In late Air from 6. Air cooler 7. Storage reservoir 8. Directional control valve
atmosphere
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Unit Two: Prepare and set-up work
This unit to provide you the necessary information regarding the following content coverage
and topics:
 Identify Faults
 methods of repairing fault
 Types of pipes and fittings
 tools and equipment
 Circuit functions and components
This guide will also assist you to attain the learning outcomes stated in the cover page.
 Identify Faults
 apply methods of repairing fault
 Identify Types of pipes and fittings
 select tools and equipment
 Map out Circuit functions and components
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2. Prepare and set-up work
2.1. Identify Faults
One of the big challenges to maintenance fluid power is finding faults. Sometimes it’s need
better experience to perform this task.
There are three maintenance levels. First-line maintenance is concerned with getting
faulty plant running again. When the cause of a fault is found, first- line staff has the choice
of affecting a first- line, on-site, repair (by replacing a failed seal, say) or changing the
complete faulty unit for a spare. This decision is based on cost, time, availability of spares,
technical ability of staff, and the environment on site and company policy.
Second-line maintenance is concerned with repair to complete units changed by first-line

maintenance staff. It should be performed in clean and well-equipped workshops. Work is
usually well-defined and is often a case of following manufacturers’ manuals. The final level
is simply the return of equipment for repair by the manufacturer. The level at which this is
needed is determined by the complexity of equipment, ability of one’s staff, cost and the turn-
2.2 Methods of Repairing Fault

There are different methods to repairing fault of fluid power operated machine and pipe lines
Regardless of the type of lines or connectors used to make up a fluid power system, make
certain they are the correct size and strength and perfectly clean on the inside. All lines must
be absolutely clean and free from scale and other foreign matter. Iron or steel pipes, tubing,
and fittings can be cleaned with a boiler tube wire brush or with commercial pipe cleaning
apparatus. Rust and scale can be removed from short, straight pieces by sandblasting,
provided there is no danger that sand particles will remain lodged in blind holes or pockets
after the piece is flushed. Some fluid power components are frequently faller during the
operation such as excessive noise, excessive heat, incorrect pressure (pressure loss), fault
operation etc…The following methods are help to identify faults and easily repair the fluid
power components.
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Remedies:
a. Any or all of the following:- b. Any or all of the following:
 Replace dirty filters;  Tighten leaking connections;
 wash strainers in solvent compatible with  Fill reservoir to proper level (with rare
system fluid; exception all return lines should be below
 clean clogged inlet line; fluid level in reservoir);
 clean or replace reservoir breather vent;  Bleed air from system; replace pump shaft
 change system fluid; change to proper pump seal.
drive motor speed;
Overhaul or replace supercharge pump; fluid c. Align unit and check condition of seals,
may be too cold. bearings and coupling. correct pressure
d, Install pressure gauge and adjust to correct

pressure
e. Overhaul or replace
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Remedies:
C, Any or all of the following:
a. Any or all of the following:  Align unit and check condition of seals and
 Replace dirty filters; bearings;
 clean clogged inlet line;  locate and correct mechanical binding;
 clean or replace reservoir  Check for work load in excess of circuit
 change system fluid; design.
 change to proper pump drive motor d, Any or all of the following:
speed;  Install pressure gauge and adjust to correct
 Overhaul or replace supercharge pressure (keep at least 125 PSI difference
pump. between valve settings).
b. Any or all of the following: e. Overhaul or replace.
 Tighten leaking connections; f. Change filters and also system fluid if
 Fill reservoir to proper level improper viscosity; fill reservoir to
 Bleed air from system; proper level
 replace pump shaft seal . g Any or all of the following:
 Clean cooler and/or cooler strainer;
 replace cooler control valve;
 Repair or replace cooler.
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Remedies
a. Replace dirty filters and system fluid.
b. Tighten leaking connections (fill reservoir to proper level and bleed air
from system).
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Remedies:
a. Fluid may be too cold or should be changed F, Repair command console or

to clean fluid of correct viscosity. interconnecting wires.
b. Locate bind and repair Adjust, repair or g. Lubricate.

replace.
h. Adjust, repair or replace counterbalance
d. Clean and adjust or replace; check condition valve.
of system fluid and filters.
e. Overhaul or replace.
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2.3 Types of pipes and fittings
Pipe and fittings are widely demanded for any piping and plumbing systems used in industrial
and commercial applications. Fittings allow pipes to be joined or installed in the appropriate
place and terminated or closed where necessary. Fittings are available in various shapes and
sizes. They can be expensive, require time, and different materials and tools to install. They
are an essential part of piping and tubing systems. There are many different types of
connectors and fittings provided for this purpose. Each type of pipe or tube requires its own
type of fitting, but usually all pipe fittings share some common features.
2.3.1 Types of Tubing, Piping, and Hose
There are three types of lines products used in transfer fluid one component to another.
1. Tubing (semi rigid),
2. pipe (rigid), and
3. Hose (flexible).
A number of factors are considered when the type of line product is selected for a particular
system. These factors include the type of fluid, the required system pressure, and the location
of the system. For example, heavy pipe might be used for a large stationary system, but
comparatively lightweight steel tubing is used in the automotive brake system.
The advantages of tubing include easier bending and flaring, fewer fittings, better
appearance, better reusability, and less leakage. However, pipe is cheaper and will handle
large volumes under high pressures. Pipe is also used where straight- line hookups are
required and for more permanent installations.
In either case, the hydraulic lines must be compatible with the entire system. Pressure loss in
the line must be kept to a minimum for an efficient system.
Pipes for hydraulic systems should be made of seamless cold-drawn mild steel. Galvanized
pipe should NOT be used because the zinc coating could flake or scale, causing damage to
the valves and pumps.
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Tubing used in fluid power systems is commonly made from steel, copper, aluminum, and, in
some instances, plastic. Each of these materials has its own distinct advantages or
disadvantages in certain applications. Some tubing materials are listed below
 Coppe r;-The use of copper is limited to low-pressure hydraulic systems where

vibration is limited. Copper has high resistance to corrosion and is easily drawn or
bent. However, it is unsatisfactory for high temperatures and has a tendency to harden
and break due to stress and vibration.
 Steel:-Tubing constructed of cold-drawn steel is the accepted standard
in hydraulics where high pressures are encountered. Steel is used because of its
strength, stability for bending and flanging, and adaptability to high pressures and
temperatures. Its chief disadvantage is its comparatively low resistance to corrosion.
There are two types of steel tubing- seamless and electric welded.
 Aluminum:-Tube is limited to low-pressure use, yet it has good flaring and bending
characteristics.
 Plastic:-Plastic tubing lines are made from a variety of materials; nylon is the most
suitable for use in low-pressure hydraulic applications ONLY.
Flexible Hose
Hose is used in fluid power systems where there is a need for flexibility, such as connection
to units that move while in operation or to units attached to a hinged portion of the
equipment. It is also used in locations that are subjected to severe vibration. Flexible hose is
usually used to connect the pump to the system. The vibration that is set up by the operating
pump would ultimately cause rigid tubing to fail. Shock-resistant, flexible hose assemblies
are required to absorb the movements of mounted equipment under both normal operating
conditions and extreme conditions. They are also used for their noise-attenuating properties
and to connect moving parts of certain equipment.
There are two basic types of hoses used in aircraft and related equipment. They are synthetic
rubber and poly tetra fluoro ethylene (PTFE), commonly known as Teflon
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Rubber hoses are designed for specific fluid, temperature, and pressure ranges and are
provided in various specifications. Rubber hoses (Figure 5) consist of a minimum of three
layers; a seamless synthetic rubber tube reinforced with one or more layers of braided or
spiralled cotton, wire, or synthetic fibre; and an outer cover. The inner tube is designed to
withstand the attack of the fluid that passes through it. The braided or spiralled layers
determine the strength of the hose; the greater the number of these layers, the greater the
pressure rating. Hoses are provided in three pressure ranges: low, medium, and high. The
outer cover is designed to withstand external abuse and contains identification markings.
Figure 7 Medium pressure synthetic rubber hose.
Synthetic rubber hose (if rubber-covered) is identified by the indicator stripe and markings
that are stencilled along the length of the hose. The indicator stripe (also called the lay line
because of its use in determining the straightness or lie of a hose) is a series of dots or dashes.
The markings (letters and numerals) contain the specification, hose size, cure date, and
manufacturer's Federal supply code number. This information is repeated at intervals of 9
inches (Figure 6).
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Figure 8 Synthetic rubber hose identification.
Size is indicated by a dash followed by a number (referred to as a dash number). The dash
number does not denote the inside or outside diameter of the hose. It refers to the equivalent
outside diameter of rigid tube size in sixteenths (1/16) of an inch. dash 8 (-8) mates to a
number 8 rigid tube which has an outside diameter of one-half inch (8/16). The inside of the
hose will not be one half inch, but slightly smaller to allow for tube thickness. The cure date
is provided for age control. It is indicated by the quarter of the year and year. The year is
divided into four quarters.
 1st quarter — January, February, March

 2rd quarter — April, May, June
 3rd quarter — July, August, September
 4th quarter — October, November, December
Synthetic rubber hose (if wire-braid covered) is identified by bands wrapped around the hose
at the ends and at intervals along the length of the hose. Each band is marked with t he same
information (Figure 9).
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Acceptance Life
The acceptance life for synthetic rubber hoses is the period of time from the cure date to the
acceptance by the organizational-, Intermediate-, or Depot-level activity. Synthetic rubber
hose and hose assemblies must have at least 8 1/2 years (34 quarters) of the shelf life
remaining upon acceptance from the first Government activity receiving the material from the
manufacturer.
Poly tetra fluoro ethylene (PTFE) (Teflon) Hose
The PTFE hose is a flexible hose designed to meet the requirements of higher operating
pressures and temperatures in present fluid power systems. This type of hose is made from a
chemical resin, which is processed and extruded into a tube shaped to a desired size. It is
reinforced with one or more layers of braided stainless steel wire or with an even number of
spiral wrap layers with an outer wire braid layer.
A PTFE hose is unaffected by all fluids presently used in fluid power systems. It is inert to
acids, both concentrated and diluted. Certain PTFE hose may be used in systems where
operating temperatures range from −100 to +500 degrees Fahrenheit (°F). PTFE is non
flammable; however, where the possibility of open flame exists, a special asbestos fire sleeve
should be used.
A PTFE hose will not absorb moisture. This, together with its chemical inertness and anti
adhesive characteristics, makes it ideal for missile fluid power systems where none
contamination clean lines In lieu of lay line marking, PTFE hoses are identified by metal or
pliable plastic bands at their ends and at intervals along their length. Usually the only
condition that will shorten the life of PTFE hose is excessive temperature. For this reason
there is no manufacture date listed on the identification tag.
Application
Flexible hose is available in three pressure ranges: low, medium, and high. When replacing
hoses, it is important to ensure that the replacement hose is a duplica te of the one removed in
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length, OD, material, type and contour, and associated markings. In selecting hose, several
precautions must be observed. The selected hose must:
1. Be compatible with the system fluid,

2. Have a rated pressure greater than the design pressure of the system,
3. Be designed to give adequate performance and service for infrequent transient
pressure peaks up to 150 percent of the working pressure of the hose, and
4. Have a safety factor with a burst pressure at a minimum of 4 times the rated working
pressure.
2.3.2 Type of fittings

The basic purposes of any pipe fitting are as follows:
 Connecting the bores of two or more pipes or tubes.

 Connecting pipe sections.
 Connecting a pipe to a different apparatus.
 Changing the direction of fluid/liquid flow.
 Maintaining or regulating the flow.
 Closing and sealing a pipe.
Some type of connector or fitting must be provided to attach the lines to the components of
the system and to connect sections of line to each other. There are many different types of
connectors and fittings provided for this purpose. The type of connector or fitting required for
a specific system depends on several factors. One determining factor, of course, is the type of
fluid line (pipe, tubing, or flexible hose) used in the system. Other determining factors are the
type of fluid medium and the maximum operating pressure of the system..
Depending on the purposes served, pipe fittings can be categorized as under:
 Pipe fittings to extend or terminate pipe runs: For example, Couplings, Adapters,
Unions, Caps and Plugs Pipe.
 Fittings to change a pipe's direction: For example , Elbows
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 Pipe fittings to connect two or more pipes: For example: Tees, Cross, Side- inlet
Elbows, Wyes
 Pipe fittings to change pipe size: For example, Reducers, Bushings, Couplings
 Pipe fittings to manage or regulate flow: For example, Valves
 Pipe fitting tools: For example, Pipe fasteners
 Pipe flanges
On the basis of the above categories, we give below an idea about the various types of pipe
fittings available in the market.
Table 3 types of pipe fitting
Selection crite ria for pipe fittings:

Pipe fittings are to be chosen considering certain factors. They are as follows:
 Connection types: When purchasing pipe fittings, you should be aware of the fact
that a fitting can have two different connector types. One end of the fitting might be
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female threaded while the other female threaded. One end might be male slip while
the other end is threaded, in the case of plastic fittings. They can also have matching
ends which can accommodate any requirement.
 Materials of construction: As a rule, the pipe fitting should be of the same material
as the material used in the making of the pipe in which it is to be fitted. However, in
some cases, materials conforming to certain codes or standards can also be used in
pipes of another material.
 Check for flow: To keep the flow consistent, the ends of pipe fittings should be
slightly larger than the rest of the pipe so that they can accommodate connections
without narrowing the inner diameter (ID) of the pipe.
 Type of fitting: Besides pipe materials, pipe fittings are identified by the type of
fitting — threaded or slip, male or female.
 Size: When measuring the size of pipe fittings, it is to be noted that the male threaded
fittings are measured to the outside edge or OD, while female fittings are measured to
the inside edge of the inlet or ID.
 Thickness: Just as pipes are available in a number of different thicknesses or
"schedules", so also the pipe fittings.
 Design: Each pipe or tube is designed to carry certain specific types of fluids, liquids,
gases, chemicals under varying conditions. Accordingly, the pipe fittings are also
available in variety of designs.
 Standards and codes: There are certain standards and codes set by various
organizations by which the different pipe fittings are graded. For example, ASTM,
ASME, BSP etc. are certain standards assigned to pipe fittings and those standards
dictate their use.
2.3.3 Sealing Devices and Materials

Sealing devices and materials prevent leakage, and contain pressure or exclude contamination
between components. The two most common classifications of seals are gaskets and
packing. There are many commercial types and forms of packing and gasket materials. The
Navy has simplified the selection of packing and gasket materials commonly used in service.
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Gaskets and Packing
Gaskets (Figure 10) depend upon mechanical compression to provide a positive seal between
two stationary joints, whereas packing generally are used where some form of relative motion
occurs between members of the joint. Packing (Figure 10) consists of deformable material,
which is shaped by adjustable compression to provide a controlled seal. Certain types of seals
(for example, the O-ring, which is discussed later) may be used either as a gasket or a
packing.
Figure 9 gasket and packing
The sealing devices and materials used in fluid power systems and components are divided
into two general classes — static seals and dynamic seals (Figure 11).
Static and Dynamic Seals
The static seal is used to prevent leakage in a mechanica l joint where there is no relative
motion between mating surfaces. Material used to create a seal between two stationary faces
of a mechanical joint are called gaskets. The gasket must function to confine liquids or gasses
within an assembly and maintain this seal under various operating conditions.
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Figure 10 Dynamic seal
To create an effective barrier, gasket material will deform to fill the space between imperfect
mating surfaces of mechanical joints to prevent fluids from leaking. This compression
requires that the joint be tightly bolted or otherwise held together. The compression of a
gasket forming a seal between mating parts is shown in Figure 11.
Figure 11 compression of gasket
2.4 Tools and equipme nt
There are different types of tools and equipment for fix to fluid power system. Such type of
works needs low to high-pressure tooling and equipment. Thus tools are jacks, cylinders,
crimpers, spreaders, cutters, splitters, breakers, drivers, torque wrenches, punches, drills,
saws, power tools and more. Some are listed below in fig
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Figure 12Bender tools
Figure 13Flange tool
Figure 14Pipe wrench and cutter
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2.5 Circuit functions and components
2.5.1 Basic fluid powe r component symbols
The installation, modification and troubleshooting of a fluid power system require an
understanding of fluid power circuit drawings. Circuit diagrams and the symbols used in
them should be drawn to the ISO 1219-1 standard. Before working on a hydraulic system,
you should obtain and trace through the circuit drawing to ensure that any potential hazards
are identified, so precautions can be taken to avoid personal injury and damage to equipment.
It is therefore necessary for you both to be capable of identifying components and to know
their function in a circuit.
In addition to knowing the symbols illustrated on the following pages, remembering the
points below will help you to understand a hydraulic system and be able to identify its
components.
1. The starting point in circuit reading is the reservoir and the termination point is the
actuator.
2. Control valves are shown in the de-energized, or neutral, position.
3. When tracing a circuit’s operation, mentally move the valve envelopes into the
position to give the desired flow.
4. Arrows are used in the envelopes to indicate fluid flow direction.
5. Fluid flow will take the path of least resistance.
6. Identify the basic type of circuit – either open or closed-loop construction.
7. Identify the type of fluid lines connecting the components in the circuit diagram.
Symbols of components
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Fluid Connectors
Line, Working (Main)
Line, Pilot (for Control)
Line, Exhaust and Liquid Drain
Flow, Direction of (Hydraulic)
Line, Flexible
Quick Disconnect, Without Checks (Connected)
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Quick Disconnect, Without Checks
(Disconnected)
Line, with Fixed Restriction
Lines, Crossing
Lines, Joining
Energy Storage & Fluid Storage
Reservoir, Vented
Reservoir, Pressurized
Reservoir with Connecting Lines Above Fluid Level
Accumulator
Accumulator, Spring Loaded
Accumulator, Gas Charged
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Accumulator, Weighted
Energy Source, Hydraulic

(Pump, Compressor, Accumulator, etc.)
Fluid Conditioners
Filter-Strainer
Cooler (inside triangles indicate heat

dissipation)
Cooler (outside triangles indicate cooling

medium is liquid)
Cooler (outside triangles indicate cooling

medium is gaseous)
Heater (inside triangles indicate heat

introduction)
Heater (outside triangles indicate heating

medium is liquid)
Heater (outside triangles indicate heating

medium is gaseous)
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Desiccators’ (Chemical Dryer)
Linear Devices
Cylinder (Hydraulic & Pneumatic), Single Acting
Cylinder (Hydraulic & Pneumatic), Double Acting, Single End Rod
Cylinder (Hydraulic & Pneumatic), Double Acting, Double End Rod
Actuators and Controls
Spring
Manual (general symbol without indicating specific type, i.e. foot, hand,
leg, arm, etc.)
Push Button
Mechanical
Detent
Pressure Compensated
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Electrical Solenoid (Single Winding)
Pilot Pressure, Remote Supply
Pilot Pressure, Internal Supply
Solenoid or Pilot, External Pilot Supply
Internal Pilot, Supply and Exhaust
Rotary Devices
Hydraulic Pump, Fixed Displacement, Unidirectional
Hydraulic Pump, Fixed Displacement, Bidirectional
Hydraulic Pump, Variable Displacement, Non Compensated,

Unidirectional
Hydraulic Pump, Variable Displacement, Non Compensated,

Bidirectional
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Hydraulic Pump, Variable Displacement, Pressure Compensated,
Unidirectional
Hydraulic Pump, Variable Displacement, Pressure Compensated,

Bidirectional
Hydraulic Motor, Fixed Displacement
Electric Motor
Heat Engine (e.g. internal combustion engine)
Instruments & Accessories
Indicating & Recording
Pressure
Temperature
Flow Rate Meter
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Accessories
Pressure Switch
Valves
Two Way Valves (2 Ported Valves)
On-Off Valve (Manual Shut-Off)
Check Valve
Check Valve, Pilot Operated to Open
Check Valve, Pilot Operated to Close
Pressure Control Valves
Pressure Relief Valve
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Sequence Valve
Four Way Valves
Servovalve, Variable Position

(indicated by parallel lines)
Two Position, Normal
Two Position, Actuated
Three Position, Normal
Three Position, Actuated Left
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Three Position, Actuated Right
Typical Flow Paths for Center

Condition of Three Position Valves
Flow Control Valves
Adjustable, Non Compensated

(Flow Control in Each Direction)
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Adjustable, Temperature & Pressure
Compensated
2.5.2 Basic Circuit diagram

A diagram may be defined as a graphic representation of an assembly or system that indicates
the various parts and expresses the methods or principles of operations. The ability to read
diagrams is a basic requirement for understanding the operation of fluid power systems.
Understanding the diagrams of a system requires having knowledge of the symbols used in
the schematic diagrams.
Example
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Description of the above Components
1. Reservoir (50 gallons minimum; elevated above pump centerline to provide gravity feed)
2. Temperature gage or thermocouple
3. Inlet pressure gage

4. Pump: 35VQ25A-11*20 (cartridge kit P/N 413421)
5. Electric motor (125 HP)
6. Outlet pressure gage
7. Pressure relief valve

8. Filter (10 micrometer nominal)
9. Cooler
10. Flow meter
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Written test
Self cheek-2
PART-I: Select the best answer from the given alternatives and write its letter on the
space provided
1.The use of steel pipe is desirable:

A. when the fluid is conducted along straight paths
B. because of its low cost
C. when use can be made of welding fittings
D. all of the above
2.When matching hydraulic fittings and components, the hydraulic technician will need to
check the:
A. type of thread
B. Angle of any sealing face (seat angle)
C. Pressure rating
D. All of the above
3.factors are considered when the type of line is selected for a particular system
A. Type of fluid
B. required pressure
C. location of the system
D. all
4.One of the fowling lines is used for permanent installations
A tubing B. line C. hose D none
5.A type of line resists vibration
A. hose B. tube C pipe D. none
PART-II: Match the items listed unde r column “A” with those expressions listed under
“B”
A B
________1. Flow, Direction of (Hydraulic)
________2. Line, Exhaust and Liquid Drain
________3. Line, Flexible
________4.Line, Working (Main)
_______5.Line, Pilot (for Control)
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Operation 1
Ope ration Sheet title: - Prepare and set-up work
Ope ration sheet purpose;- Install basic fluid power circuits
Instruction:-Read Basic fluid power circuits and install in accordance with specifications
and operational procedures
Procurers
Step 1- Read and understand work specification or working drawing
Step 2- Plan work procedures to perform the work
Step 3- Consider OHS policy
Step4- Collect fluid power components, pipes, tubes, hoses and accessories based on the
information gathered from the drawing
Step 5- Select power tools, hand tools and equipments required to accomplish the work
Step 6- Plan skill and knowledge /man power/
Step 7- Prepare work area
Step 8- fix hydraulic or pneumatic components to their respective position
Step9- Connect components with the help of piping or hose according to work specification
Step 10- Tighten couplings and joints properly
Step 11- Check work quality
Step 12- Finish work
Step 13- report /show/ the work to the responsible personnel
Step 14- clean and return tools and equipment to their proper place
Step 15 - clean work area
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Practical Demonstration
LAP Test 2
Task 1: Join and terminate pneumatic and hydraulic line/ piping
Task 2: you are given a schematic drawing of a simple hydraulic circuit below, so you are
expected to perform a complete practical installation of a circuit.
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Unit Three: Install fluid power pipes and tubes
and topics:
 place Pipes in position
 Join Pipes
 Install P ipe system
 conduct repair
 place Pipes in position and size with procedure
 perform joining pipe
 install pipe system
 Conduct repair
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3. Install fluid power pipes and tubes
3.1 place Pipes in position

To place pipe in position we should understand the overall fluid power system of the
components.
3.1.1 Sizing of Pipes

Sizing of Pipes are available in three different weights: standard (STD), or Schedule 40; extra
strong (XS), or Schedule 80; and double extra strong (XXS). The schedule numbers range
from 10 to 160 and cover 10 distinct sets of wall thickness. (See table 4)Schedule 160 wall
thickness is slightly thinner than the double extra strong.
Table 4 standard pipe size
Inside Diameter [inch]

minal Pipe
Sched. Sched. Sched. Sched. Sched. Sched. Sched. Sched. Sched. Sched.
Size OD
10 20 30 40 60 80 100 120 140 160
1/8 0.405 0.269 0.215
1/4 0.540 0.364 0.302
3/8 0.675 0.493 0.423
1/2 0.840 0.622 0.546 0.466
3/4 1.050 0.824 0.742 0.614
1 1.315 1.049 0.957 0.815
1 1/4 1.660 1.380 1.278 1.160
1 1/2 1.900 1.610 1.500 1.388
2 2.375 2.067 1.939 1.689
As mentioned earlier, the size of pipes is determined by the nominal (approximate) ID. For
example, the ID for a 1/4- inch Schedule 40 pipe is 0.364 inch, and the ID for a 1/2- inch
Schedule 40 pipe is 0.622 inch. It is important to note that the IDs of all pipes of the same
nominal size are not equal. This is because the OD remains constant and the wall thickness
increases as the schedule number increases.
For example, a nominal size 1- inch Schedule 40 pipe has a 1.049 ID. The same size Schedule
80 pipe has a 0.957 ID, while Schedule 160 pipe has a 0.815 ID. In each case the OD is 1.315
(Table 5) and the wall thicknesses are 0.133 [(1.315 - 1.049) / 2], 0.179 [(1.315 - 0.957) / 2],
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and 0.250[(1.315 - 0.815) / 2] respectively. Note that the difference between the OD and ID
includes two wall thicknesses and must be divided by 2 to obtain the wall thickness .
Tubing differs from pipe in its size classification. Tubing is designated by its actual OD
(Table 5). Thus, 5/8- inch tubing has an OD of 5/8 inch. As indicated in the table, tubing is
available in a variety of wall thicknesses. The diameter of tubing is often measured and
indicated in 16ths of an inch. Thus, No. 6 tubing is 6/16 or 3/8 inch, No. 8 tubing is 8/16 or
1/2 inch, and so forth.
Table 5 tubing size designation
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The wall thickness, material used, and ID determine the bursting pressure of a line or fitting.
The greater wall thickness in relation to the ID and the stronger the metal, the higher the
bursting pressure. However, the greater the ID for a given wall thickness, the lower the
bursting pressure, because force is the product of area and pressure.
3.2 Install and Join Pipe system
3.2.1 Installing Pipe and hose
Hose installation
1. Measure the effective cut-off length of the hose to suit the installation position
2. Clean out the hose.
3. Fit the hose fittings.

a) Hold the body by the front hexagonal section horizontally in a vice.
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b) Lightly apply oil to the hose cover over a length of about 20 mm from the end.
c. Screw the hose back in a clockwise direction by two-thirds (⅔) of a turn to back it off
from the stop (fine thread) by approximately 1.5 to 2.0 mm.
e) Remove the hose and body from the vice and visually check that the end of the hose is
back from the stop inside the body by approximately 1.5 mm.
f) Hold the stem by its hexagonal section horizontally in a vice and apply oil to
g) Position the hose and body onto the stem. Avoid ‘slicing’ of the inner hose tube.
h) Screw the hose and body onto the stem, applying some initial pressure, until the stem
thread engages the thread of the body.
i) Hold the body and hose by the front hexagonal section of the body vertically in the vice.
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J) Screw the stem in until the shoulder of the stem is between 0.0 and 1.5 m from the face of
the body.
4. Maintain a continuous screwing motion to prevent ‘cooling’ off and binding between the
stem and the inner tube.
5. Remove the hose assembly from the vice and repeat the fitting operation at the other end.
6. Install and test the hose to work order or site requirements.
Figure 15 testing hose
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Factors affecting incorrect installation of hose
Oil flow through a tube pipe or hose affects system performance and component life. The
wrong size of hose, pipe or tube can result in the following problems:
 reduced pressure
 system overheating
 vibration
 cavitations (caused by too low a pressure at pump inlet)
 slow actuator response
 turbulent flow
 High back pressure (in return or tank lines).
Figure 16 effects of incorrect line size
The above figure illustrates how high back-pressure can be caused by incorrect line sizing.
Hydraulic lines (that is, pipe and hoses) are measured by the inside diameter in millimetres.
Tube is measured by the outside diameter and wall thickness (but you use internal diameter
when utilising a flow rate monogram to determine required size).
When matching hydraulic fittings and components, the hydraulic technician will need to
check the:
 type of thread (eg JIC, BSPP, BSPT etc)
 angle of any sealing face (seat angle)
 pressure rating of the fitting.
Hoses are used where there is a degree of movement between components. A hydraulic hose
will have a line (usually consisting of the manufacture’s name and hose information) running
along its length. This is so that the technician can detect any twist in the hose during fitment.
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General hose installation principles
Remember the following:
 Do not twist the hose. High pressure applied to a twisted hose may cause loosening
of the nut or failure of the hose.
 Make sure hose has enough slack to avoid pulling at the nut and allow for thermal
contraction and movement.
 Provide as large a bend radius as possible.
 Use clamps and lacing to prevent hose from chafing.
 Do not let the hose lie against hot exhaust-carrying components.
Installation of pipe
Steel pipe is used:
 where fluid is to be conducted along straight paths
 because of its low cost compared to hose
 Where use can be made of welding fittings.
Installation procedures of pipe
A. Select pipe according to the specification

B. Cheek pipe:-All pipes shall be inspected before install to ensure that they are free
from loose contamination.
C. Prepare permanent temporally supporter :-some pipes needs permanent or temporally
D. Place the in position using supporters
E. Install gasket: - Gaskets shall be treated in accordance with manufacturers’
instructions. Gaskets shall be replaced after opening or dismantling of flange
connections. Gaskets are to be lightly smeared on the mating surface with a propriety
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anti- friction lubricant prior to fitting between the flange grooves. Anti- friction
lubricant, compatible with the flange material and process fluid shall be used.
F. Joint the pipe using different connection methods.(Flanges connecting to strain
sensitive mechanical equipment e.g. pumps, compressors, turbines, etc. shall be fitted-
up in close parallel and lateral alignment prior to tightening the bolting.)
G. flushing and testing
Pipe and tube bending
While friction increases significantly for sharper curves than this, it also tends to increase up
to a certain point for gentler curves. The increases in friction in a bend with a radius of more
than 3 pipe diameters results from increased turbulence near the outside edges of the flow.
Particles of fluid must travel a longer distance in mak ing the change in direction. When the
radius of the bend is less than 2 1/2 pipe diameters, the increased pressure loss is due to the
abrupt change in the direction of flow, especially for particles near the inside edge of the
flow.
Figure 17 bending technique
At times, new tubing may need to be fabricated to replace damaged or failed lines.
Fabrication of tubing consists of four basic operations: cutting, deburring, bending, and joint
preparation.
When constructing a tube profile from an engineering drawing, re member that stated
dimensions are usually taken from centreline measurements. This is also the most common
method of taking measurements in ‘on the job’ situations, as illustrated below.
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Figure 18 double Bending technique
Calculating the gain of a 90° bend

The dimensions of 70 mm, 150 mm and 80 mm shown in the drawing on the previous page
would be satisfactory for calculating the pre-cut length of the tube profile if we had square
corners. But, when you make a bend with the tube bender, the tube actually follows a curved
path, and short cut on the inside of the bend, as shown below.
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Calculating the gain of a 45° bend
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General rules for tube bending
1. The normal minimum bend radius should not be less than three times the tube
diameter. This is a general rule to prevent the tube from distorting – that is,
flattening, kinking or wrinkling – and the actual minimum depends upon the gauge
(wall thickness) and ductility of the tube.
2. The approximate gain for a 90° bend is equal to the tube diameter. The reduction in
tube length will vary according to the size of tube you are bending and the size of the
bend radius.
3. A tube bender will have a ‘gain scale’ on the form handle as illustrated below
Making 90° bends

When your measured distance is clamped on the left-hand side, line up your mark with the
‘90°’ mark on the link and line up the ‘0’s, as pictured below. (To produce a 45° bend, you
would line up your measured distance with the ‘45°’ mark on the link) Clamp the tube with
the latch.
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Close the shoe handle and line up the ‘0’s.
Rotate the handle until the ‘0’ and ‘90°’ Remove the tube from the bender and
line up (or the ‘45°’ mark were aligned if cheek for squareness and to ensure there
you were making that angle). are no wrinkles or flattening of the bend.
from the bender and check the
When the measured distance is taken from the right-hand side, align the mark with the ‘R’,
as shown below. This is for both 45° and 90° bends.
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Close the shoe handle so its ‘0’ lines up with the
‘0’ on the form handle.
Then rotate the handle until the required Check your bends for squareness and
mark is reached. ensure that the tube assembly lays flat on
the table.
Pipe and tube Cutting

Tubing should be cut with a tubing cutter, when available. The tubing should be marked
where it is to be cut and the cutter should be installed so the cutter wheel is over the mark and
the cutting wheel can be seen from the top view of the pipe, as shown in Figure 19. The
adjustment wheel or handle should be turned clockwise to force the cutter wheel against the
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copper. The cutter should be revolved around the tubing and turn the adjustment wheel 1/4
turn per rotation until the copper is cut through and separates.
Tubing may be cut with a hacksaw, although a tubing cutter is preferable. It is important to be
careful to cut the tubing square if it is to be flared. A fine-toothed hacksaw blade, with 32
teeth per inch, should be used when cutting copper.
Figure 19 Tube cutter
Figure 20 Tube cutter
The following steps should be taken when using a chip less cutter:
1. Select the chip less cutter according to tubing size.
2. Rotate the cutter head to accept the tubing in the cutting position. Check that the
cutter ratchet is operating freely and that the cutter wheel is clear of the cutter head
opening (Figure 20).
3. Centre the tubing on two rollers and the cutting blade.
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4. Use the hex key provided to turn the drive screw in until the cutter touches the tube.
5. Tighten the drive screw little. Do not over tighten the drive screw. Over tightening
can damage soft tubing or cause excessive wear or breakage of the cutter wheel in
hard tubing.
6. Swing the ratchet handle back and forth through the available clearance until there is a
noticeable ease of rotation. Avoid putting side force on the cutter handle. Side force
will cause the cutter wheel to break.
7. Tighten the drive screw an additional turn and swing the ratchet handle back and
forth, retightening the drive screw as needed until the cut is completed.
8. The completed cut should be 1/2 degree square to the tube centreline.
9. After the tubing is cut, all burrs and sharp edges should be remo ved from inside and
outside of the tube (Figure 18) with deburring tools. The tubing should be cleaned to
make sure there are no foreign particles remaining. A convenient method for cutting
tubing with a hacksaw is to place the tube in a flaring block and clamp the block in a
vice. After cutting the tubing with a hacksaw, all saw marks should be removed by
filing.
Figure 21 Chip less cutter. Figure 22 Properly burred tubing.
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3.2.2 Joining Pipes
Table 6 illustrates a range of methods for joining pipes. The table indicates the form of the
connection and the type of pipes on which the joint may be used.
Table 6 types of joining
TYPE OF JOINT CHA RA CT E RIS TI C

THREA DE D The jointing compound depends on the
chemical characteristics of the fluid
conveyed, the fluid temperature and whether
the joint is permanent or has to be dismantled
at a later date. Typically, a PTFE tape or
fluid is used to assist sealing.
Mainly used for steel pipes, and for
specialised plastic pipes
SOCKET & RUBBER SEAL Fusion is the use of welding for steel and
aluminium pipes, brazing for copper pipes
and hot gas for a plastic pipe.
A permanent fixture
SOCKET & SOLVENT Similar to fusion but mating of the two parts
achieved by coating with a solvent cement
Used for plastic pipes.
COMPRESSION A sleeve or ferrule is placed over the pipe

and, as the nut is tightened, the sleeve
deforms slightly to retain the pipe
FLARE D A special flaring tool is used to open out the end

of the pipe, then the deformed pipe is retained in
a special
Fitting. Widely used by plumbers for coupling
to copper pipe
FLANGE D The joint relies on a gasket between the
parallel flanges to provide sealing, and bolts
to maintain the seal pressure. The flanges
may be welded to the pipe (steel, plastic) or
be retained with a seal and separate bolts
(concrete) The flange sizes and bolt diameter
or pitches are made
to an Australian Standard so that they align
with similar flanges on valves. Ideal for pipes
that have to be occasionally separated
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Tube Flaring
Flaring is an easy and satisfactory method of joining copper tubing. The ends of the tubing
should be flared and pressed against the tapered surface of the flared fitting. Next, the flare
nut should be screwed over the end of the fitting.
An advantage of this type of connection is that it is easily disassembled when repairs are
necessary. The only thing required to disassemble this connection is to select the correct size
wrench, unscrew the flare nut that makes up the compression-type connection, and separate
the fittings. When a flare is made on tubing, every precaution should be taken to produce an
airtight and watertight joint. First, the tubing should be measured and cut to the proper length
with a tubing cutter or hacksaw. Then, the burr within the tubing should be removed by
reaming. Tubing can be flared with a flaring type tool (Figure 5-8).
Figure 23 Flaring tool.
Before a flare is made, the flare nut should be slipped on the tubing and the end of the tubing
inserted into the correct size hole in the flaring block. Then, the end of the tubing should be
extended above the face of the block twice the wall thickness of the tubing.
Next, the flaring yoke should be attached to the flaring block and the flaring cone centered
over the end of the tubing. The cone should be forced against the flaring block by rotating the
handle on the flaring yoke clockwise. After the tubing has been flared properly, assembly of
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the joint is simple. After placing the flare against the fitting, the compression nut should be
slipped against the flare and screwed on the fitting. This operation compresses the flare of the
tubing between the fitting and nut. Figure 18: Flared-tube fittings.
Tees, crosses, and elbows are self-explanatory. Universal and bulkhead fittings can be
mounted solidly with one outlet of the fitting extending through a bulkhead and the other
outlet(s) positioned at any angle. Universal means the fitting can assume the angle required
for the specific installation. Bulkhead means the fitting is long enough to pass through a
bulkhead and is designed so it can be secured solidly to the bulkhead.
For connecting to tubing, the ends of the fittings are threaded with straight machine threads to
correspond with the female threads of the nut. In some cases, however, one end of the fitting
may be threaded with tapered pipe threads to fit threaded ports in pumps, valves, and other
components.
Tubing used with flare connectors must be flared prior to assembly. The nut fits over the
sleeve and when tightened, it draws the sleeve and tubing flare tightly against the male fitting
to form a seal.
The male fitting has a cone-shaped surface with the same angle as the inside of the flare. The
sleeve supports the tube so vibration does not concentrate at the edge of the flare, and
distributes the shearing action over a wider area for added strength.
Correct and incorrect methods of installing flared-tube connectors are illustrated in Figure 19.
Tubing nuts should be tightened with a torque wrench to the value specified in applicable
technical publications.
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Figure 24 Correct and incorrect methods of installing flared fittings.
If an aluminium alloy flared connector leaks after being tightened to the required torque, it
must not be tightened further. Over tightening may severely damage or completely cut off the
tubing flare or may result in damage to the sleeve or nut. The leaking connection must be
disassembled and the fault corrected.
If a steel tube connection leaks, it may be tightened 1/6 turn beyond the specified torque in an
attempt to stop the leakage; then if it still leaks, it must be disassembled and repaired.
Under tightening of connections may be serious, as this can allow the tubing to leak at the
connector because of insufficient grip on the flare by the sleeve. The use of a torque wrench
will prevent under tightening.
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3.4 Conduct Repair
3.4.1Repairing coppe r tube
Copper pipes are connected with soldered, compression, or flare fittings. Always follow your
local code for the correct types of pipes and fittings allowed in your area. Soldered fittings,
also called sweat fittings, often are used to join copper pipes. Correctly soldered fittings are
strong and trouble free. Copper pipe can also be joined with compression fittings or flare
fittings. For repair leak copper tube or pipes follow the following step.
A. Prepare tools and material before repairing the leak part
Specialty tools and materials for

working with copper include :
(A), flaring tools (B), emery cloth coil-
spring (C),tubing bender (D), pipe joint
compound soldering(E),paste (flux) (F),
lead-free solder wire brush (G), flux brush
(H), compression fitting (I), flare fitting (J
B. Identify the diameter and wall thickness using Grade stamp information sheet (this
sheet includes the pipe diameter, the wall-thickness grade, and a stamp of approval from
the ASTM (American Society for Testing and Materials).
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C. Cut out the damaged pipe
Shut off the main water supply valve, drain the damaged water line and use a pipe cutter to
cut out a section of pipe that extends about 1 in. to each side of the leak. Start by gripping the
pipe firmly in the cutter’s jaws and tightening the cutter’s screw. Rotate the cutter in the
direction shown—as you tighten the screw handle—until the pipe snaps.
Figure 25 Cut out the damaged section
Bend flexible copper pipe with a coil-spring tubing bender to avoid kinks. Select a bender
that matches the outside diameter of the pipe. Slip bender over pipe using a twisting motion.
Bend pipe slowly until it reaches the correct angle, but not more than 90º.Cut out the
damaged section, then measure the gap and, from the sweat coupling, cut a repair piece that’s
1 in.longer than the damaged section. Maybe if the change parts has shaped follow Figure 22.
Figure 26 Slip bender Figure 27 measuring
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D. Clean before soldering
F. Soldering:- A soldered pipe joint, also called a sweated joint, is made by heating a copper
or brass fitting with a propane torch until the fitting is just hot enough tomelt metal solder.
The heat draws the solder into the gap between the fitting and pipe to form a watertight seal.
A fitting that is overheated or unevenly heated will not draw in solder. Copper pipes and
fittings must be clean and dry to form a watertight seal.
3.4.2 Repairing Hose

Most hose failures result from one of three causes: heat damage, chafing or improper
installation and assembly. Failures from all three are preventable – if one knows what to look
for.
Heat damage results from the hose resting against an exhaust-carrying component. No hose,
whether fire-sleeved or not, will withstand direct contact with an exhaust stack. Such heat
damage is usually not visible from the outside of the hose. At the point of contact, the hose
liner overheats and becomes brittle (if rubber) or melts (if non-rubber). If the hose is moved
or bent, a crack develops at the heat-damaged point.
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If you see a hose lying against a hot surface such as an exhaust, throw away the hose. You
won’t be able to see the damage but the hose liner, if it hasn’t already failed, will not be far
off doing so.
Chafing is a common cause of failure. It is almost never visible during a visual examination
and therefore missed during most inspections. Think about it: the chafe point is where the
hose rests against something – you can’t see the chafe damage without moving the hose. Pull
the hose away from any points of contact and look behind the hose. Wherever a hose is
touching something you must inspect for chafing, cutting or other damage.
Faulty installation: hoses have a tendency to expand in diameter and contract in length when
pressurised. When manufacturing and fitting hoses, this needs to be taken into consideration.
Use elbows to avoid sharp bends near the end of the hose assembly.
Maintain the minimum centreline bend radius
 Lines should normally be kept as short and free of bends as possible. However, tubing
should not be assembled in a straight line, because a bend tends to eliminate strain by
absorbing vibration and also compensates for thermal expansion and contraction. Bends
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are preferred to elbows, because bends cause less of a power loss. A few of the correct
and incorrect methods of installing tubing are illustrated in Figure 5-1.
Figure 28 Correct and incorrect methods of installing tubing
 Do not allow hose movement in more than one plane. Flexing a hose in two separate
planes of movement will cause torsion in the hose assembly. Always install the hose
assembly so that flexing occurs in one plane only and this is the same plane in which
bending occurs.
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Written Test
Self-Check -3
PART-I:
Write “TRUE” if the statement is correct and “FALSE” if it is wrong statement.
1. Sizing of Pipes are available in three different weights: standard.

2. Flaring is an easy and satisfactory method of joining copper tubing.
3. Hoses are used where there is a degree of movement between components.
PART-II: Select the best answer from the given alternatives and write its letter on the space
provided
1. a soldered pipe joint, is called -------------?
A. a sweated joint C. Solder

B. brass D. All
2. _____________ is a common cause of failure
A. Chafing C. Perching
B. Faulty D. hose
3---------------- is an easy and satisfactory method of joining copper tubing
A. Flaring C. space
B. fitting D. Chafing
PART-III: Match the items listed under column “A” with those expressions listed under “B”
_____1. Factors affecting incorrect installation of hose A Sizing of Pipes
_____2. Use clamps and lacing to prevent hose from chafing B reduced pressure
_____3. Place the in position using supporters C Impact Testing
_____4. Available in three different weights and standard D Soldering
_____5. A soldered pipe joint, also called a sweated joint E. General hose installation
Load or stress, it may fail principles
PART IV Sort ans wer
1. Explain, with the aid of sketches, three methods of joining two pipes together
2. Name and sketch three types of pipe fittings.
3. Describe four types of pipe used in engineering. Include typical properties and applications of
each type.
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Operation 1
Ope ration Sheet title: - Prepare and set-up work
Ope ration sheet purpose;-cutting pipe and tube
Instruction:-Read the given drawing and cut in accordance with specifications and
operational procedures
Procurers
Step 1- Read and understand work specification or working drawing
Step 2- Select the chip less cutter according to tubing size
Step 3- Consider OHS policy
Step4- Rotate the cutter head to accept the tubing in the cutting position.
Step 5- Centre the tubing on two rollers and the cutting blade.
Step 6- Use the hex key provided to turn the drive screw in until the cutter touches the tube.
Step 7- Tighten the drive screw little. Do not over tighten the drive screw.
Step 8- Swing the ratchet handle back and forth through the available clearance until there is
a noticeable ease of rotation.
Step9- Tighten the drive screw an additional turn and swing the ratchet handle back and
forth, retightening the drive screw as needed until the cut is completed.
Step 10- Tighten couplings and joints properly

Step 11- The completed cut should be 1/2 degree square to the tube centreline.
Step 12- After the tubing is cut; all burrs and sharp edges should be removed from inside and
outside of the tube with deburring tools.
Step 13- clean and return tools and equipment to their proper place
Step 14 - clean work area
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Operation 2
Ope ration Sheet title: - permanent joining pipes
Ope ration sheet purpose;-soldering copper pipe
Instruction:-Read the understand the given drawing and soldering the copper tube in
accordance with specifications and operational procedures
Procurers
Tubing cutter with reaming, Lead-free solder

Spark lighter ,Adjustable wrench ,Round file
tools & materials Copper pipe, Channel-type pliers ,Copper fittings
Soldering paste (flux), Emery cloth, Rag, Lead-free
solder, Wire brush
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LAP test 1
Task 1: solder copper pipe
 Note diameter of 10mm

 Length 100mm( 2pic each)
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Unit Four: Assure quality and cleanup work
and topics:
 Flush and pressure testing components
 Complete Test reports
 Clean up Work area
 Identify Flushing and pressure testing components
 Complete Test reports
 Clear Work area, tools materials and equipment’s
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4. Assure quality and cleanup work
4.1Flushing and pressure testing components

4.2.1. Flushing
Pipe Flushing is a pre-commissioning activity. Piping and pipeline systems are flushed before
commissioning the line or put into action. Pipeline or Pipe Flushing can be defined as the
activity where a sufficient quantity of fluid is pumped through the piping or pipeline section
with sufficient velocity to forcibly remove construction debris, dust, rust, mill scale, oil,
grease, or any other kind of impurities. The section of piping or pipeline system requiring
flushing is defined beforehand and then a detailed pipe flushing plan is made for execution.
Pipe flushing is usually done for pipes with sizes 10 inches or less. For larger pipes, the fluid
quantity requirement becomes so large that it slowly becomes impractical. So, full bore pipe
flushing is usually not done for pipes with size 12 inches or larger.
Types of Pipe Flushing
Depending on the fluid used for the operation, pipe flushing can be of two type s:
1. Chemical/Water flushing and

2. Oil flushing
1.Che mical flus hing is the most common method used to remove garbage elements from
the piping and pipeline systems using plain water and water with chemicals. On the other
hand, oil flushing is carried out after chemical flushing to ensure the fluid that will flow
through the pipelines are free from any kind of contamination.
2.Oil flushing is used for lube oil systems.
Working Principle of Pipe Flushing
Pipe flushing removes the unnecessary elements from the piping system by the force of
flushing fluid which passes through the system at high velocity. The force applies on the
foreign elements and becomes loose which then flows along with the flushing fluid making
the pipe and pipeline surface clean.
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Basic Pipe Flushing Guidelines
Some of the considerable pipe flushing guidelines are listed below:
 Detailed flushing plan should instruct about types, steps, and duration of flushing.
 Pipe flushing should be done using normal operation flow direction.
 Pipeline flushing should preferably be done from the highest to the lowest elevation.
 The pipe flushing activity should be supervised and inspected by a commissioning

engineer.
 Flushing should be performed through fully open flanges/ open pipe ends and never be
carried out through smaller openings such as drains or vents.
 The proper capacity of the pump shall be selected for pipe flushing activity.
 All required temporary fittings like a hose, blind flange, strainer, gasket, etc must be fitted
before flushing and shall be removed immediately after completion of pipe flushing.
 To avoid corrosion potential, the system shall be de-watered immediately after flushing
and make it dry.
4.2.3 Pressure testing components

For safe and efficient operation, fluid power systems are designed to operate at a specific
pressure and/or temperature, or within a pressure and/or temperature range.
Most fluid power systems are provided with pressure gauges and thermometers for measuring
and indicating the pressure and/or the temperature in the system. Additionally, various
temperature and pressure switches are used to warn of an adverse pressure or temperature
condition. Some switches will even shut the system off when an adverse condition occurs.
A range of instruments is used to measure fluid systems, for such variables as pressure,
temperature and flow. The following equipment is a sample of the type of instruments found
in industry, rather than in a laboratory setting.
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Pressure Gauges
MANOMETER Pressure in pipes A and B act on the fluid in the U-tube,

such that the resultant elevation (h) is an indication of the
difference in pressures between A and B. By combining
the elevation (h) with the manometer fluid’s density, the
pressure difference may be calculated. If one side of the
manometer is open to the atmospheric pressure, then (h)
represents the gauge pressure in one pipe.
Typical fluids used are coloured water, kerosene and
mercury (for higher pressures)
A piezometer may be likened to a leak in a garden hose - a

jet of water rises to an elevation equivalent to the pressure
in the hose.
The height (h) may be measured and used in conjunction

with the density of the pipe’ fluid to indicate pipe pressure.
For accurate operation, the piezometer tube height must be
measured vertically and be at a right angle to the fluid
flow.
BO UR DO N TUBE G AU GE The Bourdon tube has an elliptical cross-section that

deforms when GAUGE pressurised internally. Tube
deflection is transmitted via a gear quadrant to an
indicating needle. A negative pressure (vacuum) cause
reverse operation, or for a vacuum gauge the mechanism
linkage is reversed. The tube is made of steel (high
pressures) or bronze.
For accuracy, a gauge should only be used for the middle

80% of its scale range.
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Temperature Measuring Devices
Temperature is one of the basic engineering variables. Therefore, temperature measurement

is essential to the proper operation of a shipboard engineering plant. As a watch slander, you
will use both mechanical and electrical instruments to monitor temperature levels. You will
frequently be called on to measure the temperature of steam, water, fuel, lubricating oil, and
other vital fluids. In many cases, you will enter the results of measurements in engineering
logs and records.
MERCURY THERMOMETER A glass capillary tube has a thin- walled reservoir at

its base. The bulb is filled with mercury and as the
temperature rises, the mercury expands and rises in
the capillary tube. Graduations on or near the tube
allow the temperature to be assessed. As mercury
has a boiling point above 350°C and a freezing
point
below -35°C, this type of thermometer has a range

that is adequate for most industrial purposes. For a
lesser temperature range (-100°C to +70°C) and
cheaper construction, coloured alcohol is used
instead of mercury.
THERMOCOUPLE Dissimilar metals, such as copper and constantan

(40% nickel and 60% copper) are welded together
at the `hot junction’. If the junction is heated, a
small voltage is generated. The voltage may be
directly related to temperature. By the use of
suitable wires for the junction, temperatures up to
1650°C may be measured.
FLOW
VENTURI METER Fluid flow passes through a convergent

divergent pipe. As the fluid velocity increases at
the smaller diameter (the throat) so the pressure
in the fluid decreases. By measuring the pressure
at the entry p1 and the throat p2, the flow may be
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calculated. Some losses occur, but because of the
gradual change in diameter, a venture
meter is about 97% efficient. A venture is useful
where the fluid flow contains suspended solids.
A venture may also be placed in an open channel,
where the same changes in velocity occur, but as
the pressure cannot be measured the change of
fluid elevation is used to calculate the flow. The
venture principle is used in a carburettor, to draw
fuel into the engine air flow.
ORIFICE METER A smooth-edged orifice is placed in a pipe

carrying fluid flow. A pressure drop occurs
across the orifice, and the flow may be
calculated from the pressure drop and the orifice
diameter. The orifice is made to a Standard, so its
operating characteristics may be predicted.
An orifice meter is about 60% efficient, but is

simple to construct and install.
The pitot tube is composed of two concentric

tubes. Flow impacts on the end of the inner tube
and the total pressure in the pipe or duct (velocity
pressure plus static pressure) is measured at p1 .
The static pressure in the pipe or duct is sampled
through holes in the side of the outer tube and
measured at p2. By the use of a manometer or
differential pressure gauge, the value of p2 may
be deducted from p1 and the velocity pressure
determined.
Because the velocity near the walls of a duct is

less than at the centre, several readings are taken
across the duct (a traverse) and the average taken.
Pitot tubes are manufactured to a Standard and
are about 98% efficient. Mainly used for
measuring the velocity in a ventilation or
extraction duct.
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Pressure Switches
It is often desirable to have an alarm sound a warning, a light give a signal, or an auxiliary
control system energize or de-energize when a measured pressure reaches a certain minimum
or maximum value. A pressure switch is the device commonly used for this purpose.
One of the simplest pressure switches is the single-pole, single-throw, quick-acting type
shown in Figure 25. This switch is contained in a metal case that has a removable cover, an
electrical connection, and a pressure-sensing connection. The switch contains a seamless
metallic bellows located in its housing. Changes in the measured pressure cause the bellows
to work against an adjustable spring. This spring determines the press ure required to actuate
the switch. Through suitable linkage, the spring causes the contacts to open or close the
electrical circuit automatically when the operating pressure falls below or rises above a
specified value. A permanent magnet in the switch mechanism provides a positive snap on
both the opening and closing of the contacts. The switch is constantly energized. However, it
is the closing of the contacts that energizes the entire electrical circuit.
Another pressure switch is an electro hydraulic assembly that is used for shutting off the
pump's motor whenever the system pressure exceeds a pre-determined maximum value
(Figure 25-26). The switch is mounted on the pump housing so that the former's low pressure
ports drain directly into the pump housing.
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Figure 29 pressure switch
Figure 30 Electro hydraulic pressure switch.
This pressure switch principally consists of a flange- mounted hydraulic valve to which is
fixed a normally closed electrical limit switch. The valve consists of two hydraulically
interconnected components. The pilot valve subassembly, which bolts on the bottom of the
body (1), functions to sense system pressure continuously, and initiates pressure switch action
whenever this pressure exceeds the adjusted setting of the pilot adjustment. System pressure
is directed into the bottom port and is applied against the exposed tip of the pilot piston (5).
This piston is held on its seat by compression from the piston spring (6) which is dependent
on the position of the adjusting screw (8). Whenever the pressure causes a force large enough
to raise the pilot piston from its seat, fluid flows through an interconnecting passage to the
actuating piston (2) chamber. The accompanying fluid force raises the actuating piston
against the force of spring (3) and causes depression of the extended switch plunger. This
action disconnects the contained electrical switch, which may be connected into the pump
motor's electric supply system. Pressure switches come in many sizes and configurations
depending on how they will be used.
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4.2 Completing Test reports
After testing all components and system you should record and report your findings by
organizing them in a format given below this format is an example but different company
may use different format and procedures
Pressure test record No: Pressure test plan No: Pressure system ID:
Test parameters
Type of test pneumatic _______ Hydraulic _______
Required test pressure: Test fluid Actual test fluid temperature:
Test starting time: Test ending time:
Test duration (starting - ending time); Actual holding time:
Test equipment –pressure gauge
Type Pressure range : Calibration date:
Actual test pressure
Environmental control
Exclusion zone for safety of people (actual safe distance)
Test area controls Actual disposal of test fluid
Results
Inspection satisfactory _____ not satisfactory (explain)
Pressure test satisfactory _____ not satisfactory (explain)
Remarks :-
Mechanic performing test (point) Signature Date

Inspector witnessing test( point) Signature Date
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4.3 Cleanup Work area, tools materials and equipme nt’s
4.3.1 Cleaning work area
Cleaning your work area makes it a safe and pleasant environment for your customers to
shop. The cleaning of your work area must be carried out on a regular basis. The quick and
easy jobs can be carried out during the day, while other larger tasks such as vacuuming might
be done before the shop opens, or at the end of the day's trading. In some larger retail stores,
professional cleaners may be used for the larger tasks, but it is still your responsibility to keep
your own work area clean and tidy.
In this activity you will learn about cleaning procedures and how to dispose of waste
correctly. You will also learn how to handle spills or other potential hazards efficiently to
protect customers and your workmates from potential injury.
Poor housekeeping can be a cause of incidents, such as:
A. tripping over loose objects on floors, stairs and platforms
B. being hit by falling objects
C. slipping on greasy, wet or dirty surfaces
D. striking against projecting, poorly stacked items or misplaced material
E. cutting, puncturing, or tearing the skin of hands or other parts of the body on
projecting nails, wire or steel strapping
To avoid these hazards, a workplace must "maintain" order throughout a workday. Although
this effort requires a great deal of management and planning, the benefits are many.
Effective housekeeping results in:
A. reduced handling to ease the flow of materials
B. fewer tripping and slipping incidents in clutter- free and spill- free work areas
C. decreased fire hazards
D. lower worker exposures to hazardous products (e.g. dusts, vapours)
F. better control of tools and materials, including inventory and supplies
G. more efficient equipment cleanup and maintenance
H. better hygienic conditions leading to improved health
I. more effective use of space
J. reduced property damage by improving preventive maintenance
K. less janitorial work
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L. improved morale
M. improved productivity (tools and materials will be easy to find)
The fabrication, installation, and maintenance of all fluid lines and connectors are beyond the
scope of this training manual. However, there are some general precautionary measures that
apply to the maintenance of all fluid lines.
Regardless of the type of lines or connectors used to make up a fluid power system, they must
be the correct size and strength and perfectly clean on the inside. All lines must be absolutely
clean and free from scale and other foreign matter. Iron or steel pipes, tubing, and fittings can
be cleaned with a boiler tube wire brush or with commercial pipe cleaning apparatus. Rust
and scale can be removed from short, straight pieces by sandblasting, provided there is no
danger that sand particles will remain lodged in blind holes or pockets after the piece is
flushed. In the case of long pieces or pieces bent to complex shapes, rust and scale can be
removed by pickling (cleaning metal in a chemical bath). Parts must be degreased prior to
pickling. The manufacturer of the parts should provide complete pickling instructions.
Open ends of pipes, tubing, hose, and fittings should be capped or plugged when they are to
be stored for any considerable period. Rags or waste must not be used for this purpose,
because they deposit harmful lint which can cause severe damage to the fluid power system.
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Self cheek -4
PART-I: Write “TRUE” if the statement is correct and “FALSE” if it is wrong
statement.
1. Cleaning your work area makes it a safe and pleasant environment

2. Temperature is one of the basic engineering variables
3. Pressure Switches It is often desirable to have an alarm sound a warning
4. Pipe flushing should be done using reveres operation flow direction
5. The proper capacity of the pump shall be selected for pipe flushing activity
PART-II: Match the ite ms listed under column “A” with those expressions listed under
“B”
_____1. Effective housekeeping results in A. more effective use of space

_____2. Cleaning your work area B. a safe environment for your
_____3 is one of the basic engineering variables C. Temperature
____ 4. Advice measure by temperature D Manometer
____ 5. Advice Measure by Pressure E Thermocouple
PART-III: Select the best ans wer from the given alternatives and write its letter on the
space provided
1. Poor housekeeping can be a cause of incidents, such as

A. being hit by falling objects C. A&B
B. decreased fire hazards D. ALL
2. It is often desirable to have an alarm sound a warning
A. Pressure Switches C. less janitorial work
B. temperature D. Measuring
3. A type of temperature measuring device a glass capillary tube has a thin-walled
reservoir at its base.
A. Orifice Meter
B. Thermocouple
C. Venturi Meter
D. Bourdon tube
Author/ Copy right
List of reference
1. "Plumbing Glossary". PlumbingMart. Retrieved 2 July 2019.
2. "Use Proper Plumbing Tools To Avoid Flushing Money Down The Drain". Bangor
Daily News. April 24, 2022. Retrieved 23 April 2013.
3. "Proper Replacement Of Gaskets Important". The Victoria Advocate. Feb 26, 1963.
Retrieved December 26, 2013.
4. "Gaskets General – Non-Metallic Flat, Spiral Wound Gaskets, Camprofile Gaskets,
Metal-Jacketed Gaskets and Metallic Gaskets -". wermac.org.
5. Design Guide: Residential PEX Water Supply Plumbing Systems (2nd ed.). Home
Innovation Research Labs. 2013. p. 89. Several varieties of fitting adapters are
available for simple transition between piping systems, such as solder, threaded, and
polybutylene adapters
6. "Plumbing Glossary". PlumbingMart. Retrieved 3 July 2019
77
Participants of this Module (training mate rial) preparation
No Name Qualifi Field of Study Organization/ Mobile E-mail
cation Institution number
(Level)
1 BIRUK DESSIE B Mechanical Addis Ababa 0913419004 birukdessie27@gmail.com
TAKELE Engineering Tegbareid PTC 0967733412
2 WALIYI BENA A Manufacturing Athlete 0912305425 Waliyibena2019@gmail.co
BUSISO Technology kenenisa m
Bekele PTC
3 W/MEDHIN A Manufacturing Debremarkos 0913080488 Kenu andu1621@gmail.com
ANDUALEM Technology PTC
4 GOSA A Manufacturing Diredawa PTC 0923179949 Firesenbet gosa@gmail.com
FIRESENBET Technology
5 ERMIYAS A Manufacturing N/S/P/T/C 0911169904 ambayeerm@gmail.com
AMBAYE Technology
77

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Mechanics

Prepared by: Ministry of Labor and Skill

List of Table ................................................................................................................................... 5

Introduction to the Module .......................................................................................................... 7

Unit one: Fluid Work plan requirement................................................................................... 8

LAP Test ...................................................................................................................................... 22

Unit Two: Prepare and set-up work......................................................................................... 23

Self cheek-2 .................................................................................................................................. 52

LAP Test 2 ................................................................................................................................... 54

Unit Three: Install fluid powe r pipes and tubes ...................................................................... 55

Ope ration 1 .................................................................................................................................. 81

Ope ration 2 .................................................................................................................................. 82

LAP test 1..................................................................................................................................... 83

Unit Four: Assure quality and cleanup work .......................................................................... 84

Self cheek -4 ................................................................................................................................. 95

RPE- Respiratory Protective Equipment

OD- outside diameter

Nm- Newton Meter

HP- hour’s power

This module covers the units :

Figure 1Principle of fluid work

F. Low weight to power ratio:. .

H. Constant force or torque:

1.2 OHS standards

1.2.1 Fluid Powe r Hazards

 burns from hot, high-pressure fluid

1.2.2 Color Coding for Safety

Class Standard Identification Class of Material

Figure 3 Arrow in the picture is showing drain valve

Figure 4 the arrow in the picture is showing minims’ point

1.3 Type of components, tools and equipment

Figure 5 basic components hydraulic system

Functions of the components shown in Fig. 6 are as follows:

Figure 6basic components of pneumatics

Comparison between Hydraulic and Pneumatic Systems

Hydraulic System Pneumatic System

1 It employs a pressurized liquid as a fluid It employs a compressed gas, usually air,

PART-I: Write “TRUE” if the statement is correct and “FALSE” if it is wrong

1. Hydraulic power is especially useful when performing heavy work.

A. Reservoir B. Hydraulic actuator C. hydraulic pump D, Valves

_____2. Fresh air drawn from the atmosphere B Pressure regulator

_____3.Component of pneumatic fluid power system C Compressor

PART IV Sort answe r

1 Air compressor 2. Filter, 3. motor, 4. Air actuator

Second-line maintenance is concerned with repair to complete units changed by first-line

2.2 Methods of Repairing Fault

d, Install pressure gauge and adjust to correct

a. Replace dirty filters and system fluid.

a. Fluid may be too cold or should be changed F, Repair command console or

b. Locate bind and repair Adjust, repair or g. Lubricate.

 Coppe r;-The use of copper is limited to low-pressure hydraulic systems where

Figure 7 Medium pressure synthetic rubber hose.

 1st quarter — January, February, March

Poly tetra fluoro ethylene (PTFE) (Teflon) Hose

1. Be compatible with the system fluid,

2.3.2 Type of fittings

 Connecting the bores of two or more pipes or tubes.

Depending on the purposes served, pipe fittings can be categorized as under: