MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
- SUMMER – 2023 EXAMINATION

Subject Name: Industrial Hydraulics and Pneumatics Subject Code: 22655

Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in the model answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not applicable for
subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The figures
drawn by candidate and model answer may vary. The examiner may give credit for any equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values may vary and
there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer based on
candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual (English +
Marathi) medium is introduced at first year of AICTE diploma Programme from academic year 2021-2022. Hence if
the students write answers in Marathi or bilingual language (English +Marathi), the Examiner shall consider the
same and assess the answer based on matching of concepts with model answer.

Q. Sub Answer Marking

No. Q.N. Scheme
01 Attempt any FIVE of the following : (5x2=10) 10
a 1. Compressibility: Liquids are incompressible in nature hence they are suitable for 01 mark for
precise motion control. Hydraulic oil should have low compressibility for better any two
performance. properties
2. Viscosity: Viscosity: Hydraulic oil should have a suitable viscosity to ensure
efficient operation of the system. Viscosity refers to the oil's resistance to flow
and is usually specified at operating temperatures. It is crucial to select an oil with
the correct viscosity range for the system to achieve optimal performance.
3. Stable viscosity index: A high viscosity index signifies a relatively small change of
kinematic viscosity with temperature. Hydraulic oil should have good thermal
stability to withstand high operating temperatures without significant
degradation. It should resist thermal breakdown, oxidation, and the formation of
sludge or varnish, which can affect the oil's performance and lead to component
wear or failure
4. Demulsibility: Hydraulic systems may come into contact with water through
condensation or external sources. Hydraulic oil with good water separation
properties can quickly separate and release any water contamination, preventing
the formation of emulsions that could degrade the oil's performance.
5. Foaming tendency: Hydraulic oil should resist foaming, as air bubbles in the oil
can lead to reduced efficiency, spongy response, and cavitation within the
system. Foam can also inhibit proper lubrication, cause excessive heat
generation, and lead to component failure.
6. Oxidation: Oxidation stability is a chemical reaction that occurs with a
combination of the oil and oxygen. Over time, fluids oxidize and form acids,
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sludge, and varnish.
7. Heat dissipation: An important requirement of the fluid is to carry heat away
from the working parts. Hydraulic systems dissipate heat through the reservoir.
8. Wear resistance: Hydraulic systems often involve high-pressure conditions and
heavy loads, which can cause metal-to-metal contact and wear. A desirable
hydraulic oil should have anti-wear additives that provide an additional layer of
protection, reducing friction and wear on critical components.
9. Corrosion resistance and Rust Protection: Hydraulic oil should have effective
corrosion and rust inhibitors to protect system components, especially those
made of ferrous metals, from damage caused by moisture or environmental
contaminants.
10. Compatibility: Hydraulic oil should be compatible with the materials used in the
hydraulic system, such as seals, hoses, gaskets, and coatings. Incompatibility
could lead to degradation of these materials, leaks, or reduced system
performance.
11. Pour point: Lowest temperature at which an oil or distillate fuel will flow, when
cooled. Oil should have low pour point.
12. Flash point: Flash point is a temperature at which liquid catches fire
automatically. The flash point of good hydraulic oil must be as high as possible so
that fire possibility nullified.
13. Nontoxic: : Depending on the specific application, hydraulic oil may need to meet
certain environmental standards, such as biodegradability or low toxicity,
especially when used in sensitive ecosystems or near water sources.
b Safety in Pneumatic system: 01 mark for
1. Do not exceed the maximum permissible pressure of 600 kPa (6 bar). any two
2. Do not activate compressed air until all of the tubing connections have been safety
completed and secured. precautions
3. Do not disconnect tubing while under pressure.
4. There is a danger of injury when switching compressed air on as the cylinders
may advance and retract automatically.
5. There can be danger of accident due to tubing slipping off
6. Wear safety glasses.
7. Compressed air can cause severe damage to people. Never spray anyone with
compressed air and never let compressed air enter a human cavity, like the
nose or ear.
8. When compressed air is released through the exhaust, the air will contain oil
droplets and other particulates that can damage the eyes and respiratory
system.
9. Compressed air in pipes can cause explosions even if the reservoir is relatively
low.
10. Prior to switching systems on, the whole circuit should be inspected for
possible loose parts, damaged pipes, or any abnormal pressure.
11. If leaks are detected while using a system, work should immediately stop.
12. In the event that tubing slips off, switch compressed air supply off
immediately.
c Double-acting hydraulic cylinders are used in a wide variety of applications such as: 01 mark for
Elevators. any one
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Forklifts. application
Suspension systems in cars and other vehicles as well as airplane landing gears.
Drilling.
Earth-moving and other construction equipment.
Log-splitters.
Car transport carriers.
d 1) Gear type Pumps - External gear pump. 01 mark for
- Internal gear pump. any two
- Ge-rotor pump type
2) Vane type pumps - Constant displacement vane pump.
- Variable displacement vane pump.
3) Screw type pump - Mono Screw pump
- Twin Screw pump
4) Lobe type pump
3) Piston type pumps - Radial piston pump - Stationary cylinder block
- Rotating cylinder block
- Axial piston pump. (Swash plate & bent axis)
e Type of Control Valve 01 mark for
• Pressure control valve any two
• Relief valve type
• Reducing valve
• Unloading valve
• Counter balance valve
• Sequence valve
• Direction control valve
• Check valve
• 2/2 valve
• 3/2 valve
• 4/2 valve
• 4/3 valve
• 5/2 valve
• Flow control valve
• Fixed restriction
• Variable restriction
• FLV with reverse free flow
• Pressure compensated FLV
• Temperature compensated FLV
• Cam operated FLV
f Functions of seals and gaskets: 01 mark for
Main function of seal and gaskets is to stop leakage of fluid, to stop loss of oil under any two
pressure to the surroundings, to retain the oil under pressure within the system. type
Other functions are:
To keep dust, dirt and contaminants away from the fluid, to avoid them entering
into the oil under pressure from outside.
To avoid power loss, and to improve efficiency of the system.
To keep the surroundings clean (in case of hydraulic systems).
To avoid slippery floor, dirty surroundings, accidents and fire hazards (in case of
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hydraulic systems).
g Hydro-pneumatic systems, which combine hydraulic and pneumatic technologies, find 01 mark for
application in various industries and processes. any two
1. Machine Tools: Hydro-pneumatic systems are used in machine tools for clamping, application
lifting, and positioning operations.
2. Presses: Hydro-pneumatic systems are utilized in presses for tasks like punching,
bending, and forming.
3. Automotive Industry: These systems are employed in automotive assembly lines
for tasks such as lifting, pressing, and handling components.
4. Material Handling: Hydro-pneumatic systems are used in material handling
equipment, including conveyor systems, lift tables, and robotic arms.
5. Industrial Assembly: These systems are employed in assembly lines to control the
movement and positioning of parts during manufacturing processes.
6. Packaging Machinery: Hydro-pneumatic systems are utilized in packaging
machinery for tasks like filling, sealing, and labeling.
7. Injection Molding: These systems are used in injection molding machines to
control the clamping, injection, and ejection processes.
8. Robotics: Hydro-pneumatic systems are employed in robotic applications for
tasks such as gripping, lifting, and positioning objects.
9. Industrial Automation: These systems are used in various automation processes,
such as pick-and-place operations, part feeding, and sorting.
10. Aerospace Industry: Hydro-pneumatic systems find application in the aerospace
industry for tasks like aircraft landing gear actuation and control surface
movement.
11. Construction Machinery: These systems are utilized in construction equipment,
including cranes, excavators, and forklifts, for lifting and positioning heavy loads.
12. Material Testing: Hydro-pneumatic systems are employed in material testing
machines for tasks like applying controlled forces and measuring material
properties.
13. Food and Beverage Industry: These systems find application in food processing
and packaging equipment, including cutting, slicing, and portioning machines.
14. Medical Equipment: Hydro-pneumatic systems are used in medical devices and
equipment, such as patient lifts, surgical tables, and rehabilitation devices.
15. Waste Management: These systems find application in waste compactors and
balers for compressing and packaging waste materials.
16. Marine Industry: Hydro-pneumatic systems are utilized in marine applications,
including shipboard equipment, hydraulic steering systems, and deck machinery.
17. Agriculture: These systems are employed in agricultural machinery for tasks like
lifting and tilting implements, controlling hydraulically-driven equipment, and
irrigation systems.
18. Mining and Construction: Hydro-pneumatic systems find application in mining
and construction machinery, such as loaders, excavators, and rock drilling
equipment.
19. Renewable Energy: These systems are used in wind turbines and solar tracking
systems for tasks like adjusting the pitch of blades and orienting solar panels.
20. Entertainment Industry: Hydro-pneumatic systems find application in amusement
park rides, stage equipment, and special effects mechanisms for controlled
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movements and positioning.
02 Attempt any THREE of the following : (3 x 4 = 12) 12
a General Layout of Hydraulic System: 02 marks
for layout
and 02
marks for
working

Working of hydraulic system:

Oil reservoir is oil storage tank. Pump sucks the oil from tank and pressurizes it.
The oil is directed to port (A) or (B) of actuator by direction control valve. When
oil enters through port (A), piston will move from left to right. The oil from other
side of piston will return through port (B) via direction control valve to oil tank.
• When pressurized oil enters through port (B) piston will move from right to left
and oil from other side of piston will return through port (A).
• Flow control valve will control the flow (lit./sec.) of oil to control or monitor the
speed of piston (m/sec.). Pressure relief valve acts as a safety valve. This valve will
not allow the system pressure to increase beyond set value. Filter will arrest
foreign particles from oil and will keep the oil clean.
b Comparison between PDP and NPDP: 01 mark for
any one
Non-positive displacement pump difference
Sr. No. Positive displacement pump
(Roto-dynamic Pump)
In PDP, the moving component In NPDP, the moving component gives
1. carries the liquid along with it from off its energy to the liquid, due to this;
inlet port to outlet port. the liquid will be thrown from inlet
ports towards outlet.
In PDP, discharge remains constant In NPDP, as pressure increases,
2. discharge reduces and become zero at
irrespective of increase in pressure. maximum pressure.
More discharge, less pressure, high
3. Less discharge, more pressure.
speed.
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4. Priming is not necessary for PDP Priming is necessary for NPDP
5. Foot valve is not needed for PDP Foot valve is needed for NPDP.
In PDP, the delivery valve should In NPDP, the delivery valve should be
6. not be closed while the pump is opened slowly only after max. Pressure
running. is reached.
Pressure relief valve is necessary as Pressure relief valve is not needed,
7. a safety device in order to safe because pressure does not increase
guard system components beyond certain limit.
Examples are: Reciprocating pump,
8. Rotary pump: Gear, Vane and Examples are: Centrifugal Pump, Axial
Piston type pumps pump.
c Construction 02 mark for
This valve is used to operate double acting cylinder and bidirectional motor. construction
It has four ports namely, Pump port or inlet port “P”, Cylinder port “A” Cylinder and 02 mark
port “B” and Tank port “T”. for working
It has three positions of its spool.

Working
In first position, there is connection from P to A and B to T, hence cylinder/motor
moves in one direction.
In the other position of spool, there is connection from P to B and A to T; hence
the cylinder/motor runs in opposite direction.
In the middle position of spool, the cylinder or motor stops, it will not move in

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any direction this position also called as 'Closed Centre Position'. This position is
shown in Fig. We have shifted the spool in such a manner that all ports are closed
to each other. No flow from port P to A or B and no flow from port A and B to R.
When DC valve attains this position, pressurised oil returns to reservoir via
pressure relief valve.
d FRL unit is a device consisting of Air Filter, Air Regulator and Air Lubricator. 02 mark for
any two
function
and 02 mark
for figure

The three components work together to do the following:

Filters remove water, dirt and other harmful debris from an air system. This is
often the first step in improving the air quality.
Regulators adjust and control the air pressure of a system to ensure that down-
line components do not exceed their maximum operating pressures. This is the
second step in the FRL system.
Lubricators reduce the internal friction in tools or equipment by releasing a
controlled mist of oil into the compressed air. This is often done last and/or right
before the component needing lubrication.
03 Attempt any THREE of the following : (3 x 4 = 12) 12
a Principal: 01 mark for
The principle of working of an external gear pump involves the use of two principle, 01
interlocking gears to create fluid flow. It operates based on the positive displacement mark for
principle, meaning that a fixed volume of fluid is moved with each revolution of the working and
gears. 02 mark for
Working: figure
1. Pump Housing: The pump consists of a housing or casing that encloses the gears
and provides support for the components.
2. Gear: The pump has two gears: a larger drive gear (called the "driven gear" or
"ring gear") and a smaller driven gear (called the "drive gear" or "pinion gear").
These gears have precise tooth profiles and mesh together in the housing.
3. Inlet Port: The pump has an inlet port through which fluid enters the pump. It is
typically located at the center of the pump housing.
4. Outlet Port: The pump also has an outlet port through which fluid exits the pump.
It is usually positioned on one side of the pump housing.
5. Gear Rotation: The drive gear is connected to a power source, such as an electric
motor or an engine, which causes it to rotate. The driven gear, being in mesh with
the drive gear, rotates in the opposite direction due to the interlocking teeth.
6. Fluid Intake: As the gears rotate, a void or suction chamber is created on the inlet

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side of the pump. This causes fluid to be drawn into the pump through the inlet
port.
7. Fluid Enclosure: As the gears continue to rotate, the fluid is enclosed between the
gear teeth and the pump housing. The fluid is trapped in the space between the
teeth of the two gears and the housing, preventing it from flowing back to the
inlet side.
8. Fluid Discharge: As the gears rotate further, the trapped fluid is carried around
the housing, gradually moving towards the outlet side of the pump.
9. Pressure Increase: As the fluid is carried around the housing, the volume between
the gear teeth and the housing decreases. This reduction in volume causes the
fluid to be pressurized, resulting in an increase in fluid pressure.
10. Fluid Release: Once the fluid reaches the outlet side of the pump, it is discharged
through the outlet port to the desired location or system.
11. Gear Separation: As the gears continue to rotate, they move away from each
other, creating a larger void or suction chamber on the inlet side of the pump.
12. Repeat Process: The cycle repeats as the gears rotate, drawing in more fluid,
trapping and pressurizing it, and then discharging it.
The external gear pump operates efficiently, delivering a relatively constant flow rate and
generating high pressures. It is commonly used in various industrial applications,
including hydraulic systems, lubrication systems, fuel transfer, and other fluid handling
processes.

b Need of pressure and temperature compensation in flow control valve 02 mark for
To control the rate of flow of oil, we use flow control valve. By opening the flow explanation
control valve, we can increase the flow of oil. And by closing it, we can reduce the of each
flow. We can keep the valve opening for a required flow rate.
But, flow rate does not remain constant. It gets affected by the changes in
pressure and temperature of oil.
 If inlet pressure is more, then there will be increase in flow.
 If outlet pressure is more, then there will be reduction in flow.
 If temperature of oil is more, then due to decrease in viscosity, there will be
increase in flow rate.
So, in order to maintain constant flow rate,
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“Any change in flow rate which happens due to changes in pressure and
temperature should be corrected (compensated)”.
And this is done by the compensation mechanism of the valve.
c Meter-out Hydraulic circuit: 04 mark for
forward
stroke OR
reverse
stroke
circuit with
complete
labelling

d Any one
circuit 04
mark with
complete
labelling

04 Attempt any THREE of the following : (3 x 4 = 12) 12

a Function of pressure control valve 02 mark for
Pressure control valves are used to control the pressure of oil. any two
function of
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By controlling the pressure of oil, we can control the force developed by the each
actuator.
Pressure Regulation: The pressure control valve monitors the pressure in the
hydraulic system and regulates it to a predetermined set value. When the
pressure exceeds the set limit, the valve opens to allow excess fluid to bypass and
return to the reservoir, thus preventing over-pressurization.
System Protection: The pressure control valve protects the hydraulic system from
damage caused by excessive pressure. By relieving excess pressure, it prevents
potential failure of components, seals, hoses, and other system elements.
Load Control: In systems with variable loads, the pressure control valve ensures
that the desired pressure is maintained, regardless of changes in the load. It
adjusts the fluid flow to match the requirements of the load, maintaining
consistent performance and preventing damage.
Pressure Sequencing: In complex hydraulic systems, pressure control valves are
used to sequence or prioritize the application of pressure to different
components or actuators. They ensure that pressure is distributed in the desired
order and at the appropriate levels.
Function of flow control valve
Flow control valve is used to control the rate of flow of fluid, by which, we can
control the speed of the actuator.
If flow rate of oil is more, then cylinder will fill quickly and hence the piston will
move faster.
Regulate the power available to the sub-circuits by controlling the flow of them.
Proportionally divide or regulate the pump flow to various branches of the
circuits.
Speed of the actuator is proportional to the rate of flow. Hence controlling the flow
controls the speed of actuator. This is achieved by flow control valves.
b 02 mark for
sketch and
02 mark for
explanation

Working of pressure relief valve

Pressure relief valve work similar to the relief valve of a pressure cooker of our
kitchen.
If pressure inside the system increases above pre-set level, this valve opens to
release the oil back to tank, so that the system pressure comes to normal.
Relief valve consists of an adjusting screw, two supporting plates on either side of
the spring, and a conical poppet which are mounted inside the valve body as
shown in the Fig.
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When the pressure at inlet increases above pre-set limit, the conical poppet
moves inside against the spring force, and creates a passage for oil to flow to
outlet.
The outlet of relief valve is connected to the reservoir in hydraulic systems, so
that oil flows to the reservoir tank.
Once the pressure comes to normal, the conical poppet sit back in its position on
the seat, closes the passage from inlet to outlet.
c 02 mark for
sketch and
02 mark for
working

Working of a centrifugal compressor:

Inlet: The process begins with the gas or air entering the compressor through the
inlet. The air flows into the center of the compressor and is directed towards the
rotating impeller.
Impeller: The heart of the centrifugal compressor is the impeller, which consists
of a series of curved blades mounted on a rotating shaft. As the impeller rotates
at high speed, it creates a high-velocity air flow due to centrifugal force.
Centrifugal Force: The rotation of the impeller generates a centrifugal force that
pushes the air radially outward. This force causes the air to gain kinetic energy
and increase in velocity.
Diffuser: After leaving the impeller, the high-velocity air flow enters the diffuser
section. The diffuser is a diverging passage that converts the kinetic energy of the
gas into pressure energy.
Deceleration and Pressure Rise: In the diffuser, the air flow gradually slows down
and expands, which leads to a decrease in velocity and an increase in pressure.
This deceleration and expansion convert the kinetic energy into pressure energy.
Outlet: The compressed air exits the diffuser at a higher pressure than the inlet
pressure. It then passes through the outlet of the compressor and is directed
towards the desired application or further processing.
Cooling and Lubrication: During the compression process, the air can heat up due
to the increase in pressure. Therefore, centrifugal compressors often have cooling
mechanisms, such as intercoolers or aftercoolers, to remove excess heat from the
compressed air. Additionally, the compressor's bearings and rotating components
require lubrication for smooth operation.
Power Source: Centrifugal compressors are typically driven by an external power
source, such as an electric motor or a gas turbine. The power source supplies the
necessary energy to drive the impeller rotation and the compression process.
d Hydraulic circuit of milling machine: 01 mark for
labelled and
03 mark for

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sketch

e Remedies and fault detection in pneumatic circuits involve identifying and addressing 01 mark for
issues that may arise in the system. Following are some common faults in pneumatic any one
circuits and the corresponding remedies and fault detection methods: fault and
1. Air Leakage: their
Fault Detection: Look for audible hissing sounds, visual inspection of connections remedy (any
and fittings for air leaks, or use a leak detection spray to identify leak points. four)
Remedies: Tighten loose fittings, replace damaged seals or gaskets, repair or
replace faulty valves or cylinders, use thread sealant or Teflon tape on threaded
connections, and ensure proper maintenance of pneumatic components.
2. Insufficient Air Pressure:
Fault Detection: Measure and monitor the air pressure using pressure gauges at
key points in the system.
Remedies: Check the air compressor for proper functioning, ensure the pressure
regulator is correctly set, inspect and clean filters, remove any obstructions in the
air lines, and check for leaks that may be causing pressure loss.
3. Inconsistent or Slow Actuator Movement:
Fault Detection: Observe the actuator movement for irregularities, measure
actuator response times, and check for proper air pressure.
Remedies: Ensure the actuator is properly sized for the application, check for
binding or misalignment in the mechanical components, clean or replace filters
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and lubricate pneumatic cylinders, check for air restrictions or inadequate airflow,
and verify proper actuator and valve functioning.
4. Valves Sticking or Failing to Operate:
Fault Detection: Observe valve operation, listen for abnormal sounds, and check
for any physical blockages.
Remedies: Clean or replace faulty valves, check for proper lubrication, inspect and
replace worn seals or gaskets, ensure proper air supply and pressure to the
valves, and verify electrical signals or solenoid operation if applicable.
5. Excessive Condensation or Moisture in the System:
Fault Detection: Observe moisture accumulation in filters, air lines, or pneumatic
components.
Remedies: Install and maintain proper moisture traps or separators, drain
condensate from filters and air lines, use air dryers or desiccant filters, ensure
proper insulation of air lines in humid environments, and monitor and maintain
proper system humidity levels.
6. Incorrect Air Flow or Direction:
Fault Detection: Observe air flow direction, check valve position indicators or
marks, and measure air pressure at various points in the circuit.
Remedies: Verify correct valve installation and orientation, check for blockages or
restrictions in air lines, ensure proper alignment and connection of tubing and
fittings, and confirm that valves are properly actuated and controlled.
7. Excessive Air Pressure:
Fault: Excessive air pressure can occur due to malfunctioning pressure regulators,
incorrect adjustments, or blocked exhaust vents.
Detection: Monitor pressure gauges or pressure sensors to check if the pressure
exceeds the specified range.
Remedies: Inspect and calibrate pressure regulators, adjust pressure settings to
the appropriate level, and clear any obstructions in exhaust vents.

Fault: Contamination in pneumatic systems can arise from the presence of dirt,
debris, moisture, or oil particles, which can affect the performance and reliability
of components.
Detection: Monitor system performance, inspect filters for clogging, and observe
any abnormalities in component operation.
Remedies: Install and maintain proper filtration systems, regularly replace and
clean filters, drain moisture traps, use proper lubricants, and implement proper
maintenance and cleaning procedures.
9. Component Malfunction:
Fault: Components like valves, actuators, or cylinders can experience
malfunctions due to wear and tear, dirt accumulation, or misalignment.
Detection: Monitor system performance, observe abnormal behaviour in
component operation, or conduct visual inspections for physical damage.
Remedies: Repair or replace malfunctioning components, clean or lubricate as
necessary, and ensure proper alignment and adjustment.
10. Excessive Noise or Vibrations:
Fault Detection: Excessive noise or vibrations can indicate mechanical issues or
improper component operation.

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Detection Techniques: Listen for unusual or excessive noise, inspect components
for loose fittings or worn parts and check for vibrations in the system.
Remedies: Tighten loose connections, lubricate moving parts, replace worn or
damaged components and ensure proper alignment of components.
Regular maintenance, inspection, and testing are essential for detecting and addressing
faults in pneumatic circuits. Additionally, using pressure gauges, flow meters, and other
monitoring devices can help in detecting abnormalities or deviations from expected
performance. It is important to follow manufacturer guidelines, maintain cleanliness, and
ensure proper installation and operation of pneumatic components to minimize faults
and maximize system efficiency.
05 Attempt any TWO of the following : (2 x 6 = 12) 12
a We can use or suggest Telescopic cylinder in the given condition described in question 01 mark for
statement suggestion,
Sketch: 01 mark for
justification,
02 mark for
figure and
02 mark for
working

Explanation:
A telescopic cylinder (shown in Fig.) is used when a long stroke length and a short
retracted length are required. The telescopic cylinder extends in stages, each
stage consisting of a sleeve that fits inside the previous stage.
They generally consist of a nest of tubes and operate on the displacement
principle. The tubes are supported by bearing rings, the innermost (rear) set of
which have grooves or channels to allow fluid flow.
The front bearing assembly on each section includes seals and wiper rings. Stop
rings limit the movement of each section, thus preventing separation. When the
cylinder extends, all the sections move together until the outer section is
prevented from further extension by its stop ring.
The remaining sections continue out-stroking until the second outermost section
reaches the limit of its stroke; this process continues until all sections are
extended, the innermost one being the last of all.
b A pilot-operated check valve (POCV) is a type of check valve that allows fluid flow in one 02 mark for
direction while blocking it in the opposite direction. It consists of two main components: neat sketch,
a main check valve and a pilot valve. The pilot valve controls the opening and closing of 02 mark for
the main check valve based on pressure differentials. construction
Construction: and 02 mark
A typical pilot-operated check valve consists of the following components: for working
Main Check Valve: The main check valve is typically a spring-loaded poppet or disc that
allows flow in one direction while preventing reverse flow. It is housed within the valve
body and has an inlet port and an outlet port.
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Pilot Control Valve: The pilot control valve is a smaller valve connected to the main check
valve. It consists of a poppet or spool, spring, and pilot ports. The pilot valve is designed
to control the opening and closing of the main check valve.

Working:
Normal Closed Position: In the normal closed position, the main check valve is
closed, preventing reverse flow. The spring in the main check valve applies force
to keep the poppet or disc pressed against the valve seat, blocking flow from the
outlet to the inlet.
Pilot Pressure Applied: When pilot pressure is applied to the pilot control valve, it
overcomes the force of the spring in the pilot valve and shifts the pilot valve's
poppet or spool.
Opening of the Main Check Valve: The pilot valve, when shifted, allows the pilot
pressure to reach the control chamber behind the main check valve's poppet or
disc. The pilot pressure acts on a larger effective area, counteracting the force of
the spring in the main check valve.
Main Check Valve Opens: With the pilot pressure overcoming the spring force,
the main check valve's poppet or disc is lifted off the valve seat, allowing flow in
the forward direction from the inlet to the outlet.
Pilot Pressure Released: When the pilot pressure is released or drops below a
certain threshold, the pilot control valve's spring returns the pilot valve to its
closed position.
Closing of the Main Check Valve: As the pilot pressure is relieved, the spring in the
main check valve becomes the dominant force, causing the poppet or disc to
return to its closed position, blocking reverse flow.
The pilot-operated check valve operates by using a pilot pressure to control the opening
and closing of the main check valve. It allows flow in one direction when the pilot
pressure is sufficient to overcome the spring force, and blocks flow in the reverse
direction when the pilot pressure drops or is removed. This design enables precise
control and prevents undesired flow in hydraulic systems, providing additional safety and
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functionality.
c Construction: 02 mark for
Fig. shows a time delay valve. It has an in-built reservoir, flow control, a check valve, and neat sketch,
pilot operated 3/2 direction control valve. 02 mark for
1. Valve Body: The valve body houses the internal components of the time delay construction
valve. It is typically made of metal or durable plastic and has inlet and outlet ports and 02 mark
for fluid flow. for working
2. Control Chamber: The control chamber is a small chamber within the valve body
that contains a diaphragm or piston. The control chamber is pressurized or
depressurized to control the operation of the valve.
3. Adjustable Orifice: The time delay valve usually has an adjustable orifice that
controls the rate of fluid flow through the valve. The orifice can be manually
adjusted to set the desired time delay.
4. Spring: The valve is equipped with a spring that applies force to the diaphragm or
piston. The spring determines the time delay duration and can be adjusted to
change the delay period.

Working:
It is simply a 3/2 direction control valve, which is impulse operated from one side.
Time delaying is achieved by delaying the impulse actuation. The valve has an
inbuilt air reservoir and in-built non-return flow control valve.
When impulse is applied to port “P1” for valve actuation, the air passes through
needle control valve, which controls the rate of flow, further the valve spool is
not actuated until the air reservoir is filled completely and pressure is built-up.
(This time difference between impulse application at “P1” and actual spool
actuation is the “delay”, which is adjustable through needle valve).
The time delay function is obtained by controlling the air flow rate to or from
the reservoir by using the throttle valve. Adjustment of throttle valve permits fine
control of time delay between minimum and maximum times.
06 Attempt any TWO of the following : (2 x 6 = 12) 12
a Routine maintenance procedures for the hydraulic circuit of a shaper machine typically 01 mark for
involve several steps to ensure its smooth operation. any one
1. Safety Precautions: Before performing any maintenance tasks, ensure that the procedure
machine is powered off and disconnected from the electrical supply. Follow step
proper lockout/tagout procedures to prevent accidental startup
2. Inspection: Start by visually inspecting the hydraulic circuit for any signs of leaks,
loose connections, or damaged components. Look for oil puddles or drips, check
the hoses, pipes, valves, and fittings for any wear or corrosion, and inspect the

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hydraulic reservoir for proper oil level.
3. Cleanliness: Keep the hydraulic circuit clean and free from dirt, debris, and
contaminants. Use compressed air or a lint-free cloth to remove any accumulated
dust or particles that could potentially clog the system.
4. Fluid Level Check: Verify the hydraulic fluid level in the reservoir. If needed, top
up the fluid using the manufacturer-recommended hydraulic oil, ensuring it
meets the required specifications. Avoid overfilling the reservoir.
5. Fluid quality check: Assess the condition of the hydraulic fluid. If it appears dirty,
contaminated, or has exceeded its recommended service life, consider draining
and replacing the fluid. Refer to the machine's manual for the recommended fluid
change intervals and procedures.
6. Filter Cleaning/Replacement: Hydraulic filters prevent contaminants from
entering the system and ensure the fluid remains clean. Depending on the
machine's usage and manufacturer recommendations, clean or replace the
hydraulic filters regularly to maintain proper filtration.
7. Lubrication: Check the lubrication points in the hydraulic circuit, such as pivot
points, cylinders, and slides. Apply appropriate lubricants as recommended by the
manufacturer to ensure smooth operation and minimize wear.
8. Hose inspection: Examine the hydraulic hoses for any signs of wear, cracks, or
leaks. Replace any damaged hoses promptly to prevent fluid leakage or system
failure. Ensure that all hose connections are tight and secure.
9. Pressure Testing: Test the hydraulic system's pressure to ensure it falls within the
recommended range. Use a pressure gauge or a calibrated test gauge to measure
the pressure accurately. If the pressure is outside the specified limits, consult a
professional for further troubleshooting and adjustments.
10. Component Inspection: Inspect the hydraulic components, including pumps,
valves, actuators, and cylinders, for any signs of damage, wear, or leaks. Replace
or repair any faulty components to maintain the system's efficiency.
11. Seals and O-Rings: Check the seals and O-rings in the hydraulic system for any
signs of damage or wear. Replace any worn-out seals to prevent leaks and
maintain proper sealing.
12. Operational Testing: Once you have completed the maintenance tasks, test the
hydraulic circuit by operating the shaper machine. Observe its performance,
listen for any unusual noises, and check for leaks or other abnormalities. If any
issues arise, address them promptly.
Consult the specific manufacturer's guidelines and recommendations for the shaper
machine working with, as the maintenance procedures may vary slightly. Regular
maintenance and inspection will help keep the hydraulic circuit of the shaper machine in
optimal condition and ensure its longevity and efficient operation.
b A primary function of sequence valve is to direct flow to different components of the 03 mark for
circuit in a predetermined sequence. circuit
It is a pressure actuated valve which senses a certain change in pressure from the diagram ,
set value. (forward or
It then takes the actions to direct the fluid in a definite predetermined order. It return
also maintains the requisite minimum pressure in the primary line while the stroke), 1
secondary operations occur. mark for
Figure shows operating principle of a direct acting, normally closed sequence labelling
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valve. and 02 mark
for
explanation

Working of the Circuit:

Initial State: In the resting state, no actuator is activated, and no compressed air flows
through the circuit.
Actuator C2 Activation: The input signal activates a directional control valve, allowing
compressed air to flow to Actuator C2.
Actuator C2 Extension: The compressed air extends Actuator C2, performing the
intended task or operation.
Pressure Build-Up: As Actuator C2 extends, the pressure in the primary circuit increases.
Sequence Valve Operation: The pressure in the primary circuit reaches a predetermined
level set by the sequence valve.
Actuator C1 Activation: Once the pressure reaches the set value, the sequence valve
opens, allowing compressed air to flow to Actuator C1.
Actuator C2 Extension: The compressed air reaches Actuator C1, causing it to extend and
perform its designated operation.
Completion of Actuator C1 Operation: Once Actuator C1 completes its operation, the
compressed air supply to Actuator C1 is shut off.
Resetting the Circuit: The input signal is reset or deactivated, returning the circuit to its
initial state, ready for the next cycle.
The sequence valve in the pneumatic sequence circuit ensures that Actuator C2 is
activated first and completes its operation before Actuator C1 is activated. The sequence
valve controls the pressure threshold that must be reached in the primary circuit before
allowing compressed air to flow to the subsequent actuator.
c Speed Control of DA Cylinder: 03 mark for
Speed control circuits are adopted to control speed of actuators. This speed control is circuit
achieved by adopting flow control valve in circuit. diagram ,
Explanation: (forward or
The two flow control valves are placed in two supply lines of DA cylinder. As position return
shown in the circuit (Fig.), pressure port 'P' is connected to inlet port 'A' of DA cylinder. stroke), 1
Now we can control the flow of air leave from DA cylinder, through port B, by using mark for
variable flow control valve 'F2'. If more flow will be allowed, then more air will leave out labelling

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cylinder and piston will move towards right with more linear speed. If less air is allowed and 02 mark
to flow, the linear speed of piston will be low. for
When push button is pressed (Fig.), then pressure port 'P' will be connected to port 'B' of explanation
DA cylinder and exhaust port R will be connected to port A of DA cylinder. Here also by
controlling flow control valve F1 we can control the speed of piston. During this stroke,
the air from earlier stroke in the other side of piston will be exhausted through flow
control valve F1 via DC valve.
During this return, the air flows to DC valve through throttled chamber of flow control
valve. Air will not flow through check valve because, it is unidirectional valve.
This arrangement of circuit design with non-return flow control valve is called 'exhaust
throttling' or 'Throttle out'.

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WINTER – 2022 EXAMINATION
Model Answer

Subject Name: Industrial Hydraulics and Pneumatics Subject Code: 22655

Important Instructions to examiners: XXXXX
1) The answers should be examined by key words and not as word-to-word as given in the model answer
scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not
applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The
figures drawn by candidate and model answer may vary. The examiner may give credit for any equivalent
figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values
may vary and there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer
based on candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent
concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual
(English + Marathi) medium is introduced at first year of AICTE diploma Programme from academic year
2021-2022. Hence if the students in first year (first and second semesters) write answers in Marathi or
bilingual language (English +Marathi), the Examiner shall consider the same and assess the answer
based on matching of concepts with model answer.

Q. Sub Answer Marking

No. Q. N. Scheme

1 Attempt any FIVE 0f the Following 10

a) Draw IS symbol for 01 marks

each
i) 4/3 Directional control Valve

i) Sequence Valve

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Q. Sub Q. Answer Marking

No. N. Scheme

b) I)Viscosity: - The viscosity of a fluid is a measure of its resistance to shear or angular 01 marks
deformation. each

Or Viscosity is a measure of a fluid's resistance to flow.

ii)Specific Weight :- Specific weight is defined as weight per unit volume

Linear Actuator Material Handling. Robotics. ...

c)
Food and Beverage Manufacturing. ...
01 marks
Window Automation. ... each (
Agricultural Machinery. ... Minimu
Cutting Equipment. ... m2
Valve Operation applicati
on of
Rotary Actuator Clamps or pick-and-place handlers farm applications for each.
rotating arms, booms in industries for positioning,
transferring & clamping parts.

d)
Factors to be considered while selecting pump

1. Liquid Properties-
2. Pump Capacity (Flow Rate and Pressure of oil)
Minimu
3. Efficiency of the pump
m 4 , half
4. Speed of pump
each.
5. Ease of Use
6. Environmental Considerations
7. Control Systems

e) Different functions of valves

1 Industrial system, and in any piping system, valves are used to restrict stop or
control the flow of fluid.
2 Regulating flow and pressure within a piping system. Minimu
3 Controlling the direction of flow within a piping system m2,1
4 Throttling flow rates within a piping system. each.

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f) Hydraulic Filter Pneumatic Filter

Suction Filters and Strainers Air Filter Types
Fiberglass, polyester, washable, pleated and Minimu
electrostatic filters m 4 , half
each.
Spin-On Filters Water separators.
Reservoir Breather Filters Particulate filters.
Adsorbing filters.

g) Common faults that can be observed in Pneumatic System

Minimu
i) Low pressure m 4 , half
ii) High Temperatures each
iii) Particulate Contamination
iv) Compressor Stalling, Failure, And Faults
v) Audible And Visible Leaks.
Attempt Any THREE of the following: 12
2 a)

Advantages and limitations of hydraulic and pneumatic systems (reference points)

Parameters hydraulic systems pneumatic systems
2 marks
Complexity Moderately complex system Simple system each
Peak Power Very high high
Speed Moderate Very high
Load Ratings Very high high
Environmental Low High noise levels
Purchase Cost High low
Operating Cost High Moderate
Maintenance Cost High low

b) Tandem Cylinder:-

02+02

A tandem cylinder, shown in Figure , is used in applications where a large amount of

force is required from a small-diameter cylinder. Pressure is applied to both pistons,
resulting in increased force because of the larger area. Hence at the piston rod, we can
get double force during movement of pistons.
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c) Check valve
The simplest DCV is a check valve. A check valve allows flow in one direction, but blocks
the flow in the opposite direction. It is a two-way valve because it contains two ports.

In Figure light spring holds the ball against the valve seat. Flow coming into the inlet 02+02
pushes the ball off the seat against the light force of the spring and continues to the outlet.
A very low pressure is required to hold the valve open in this direction. If the flow tries to
enter from the opposite direction, the pressure pushes the ball against the seat and the flow
cannot pass through.

d) Any one rotary compressor with sketch

Rotary compressor units are classified into three general groups, ( Any one)
1. Slide vane-type,
2. Lobe-type, and 02+02
3. Screw-type.  This is a positive-displacement pump that
Slide vane-type, consists of vanes mounted to a rotor that
rotates inside a cavity.
 The vane-type compressor consists of a
cylindrical rotor with longitudinal slots in
which radial sliding vanes are fitted.
 The rotor is positioned eccentrically within a
cylindrical housing.
 The spaces between adjacent vanes form
pockets of decreasing volume from a fixed
inlet port to a fixed discharge port.

Lobe type air compressor: it is a rotary type of compressor

Lobe-type
consisting of two rotors which are driven externally.
One rotor is connected to drive and second is connected to gear.
These two rotors have two or three lobes having epicycloids,
hypocycloid or involutes profiles.
In the figure two lobes compressor is shown with a inlet
arrangement and receiver. A very small clearance is maintained
between surfaces so that wear is prevented.
Air leakage through this clearance decreases efficiency of this
compressor. During rotation a volume of air V at atmospheric
pressure is trapped between left hand rotor and casing . this air is
positively displaced with change in volume until space is opened
to high pressure region.
At this instant some high pressure air rushes back from the
receiver and mixed with the blower air until both pressure are
equalized.
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Screw type
In a screw compressor one of the shafts is driving shaft and the other is driven shaft. The
driving shaft is connected to the driven shaft via timing gears which help to match speeds
of both the shafts. The driving shaft is powered by an electric motor generally. The two
shafts are enclosed in an airtight casing.
The working cycle of the screw compressor has three distinct phases as following:
i) Suction process
ii) Compression process
iii) Discharge process.
i) Suction process - As the rotors rotate, air is drawn through the inlet opening to fill the
space between the male lobe and the female flute.
As the rotor continues to rotate, the air is moved past the suction port and sealed in
the interlobe space.
ii) Compression process -As the main rotor turns, the air trapped in the ineterlobe space
is moved both axially and radially.
The air is compressed by direct volume reduction as the enmeshing of the lobes
progressively reduced the flute volume and compression occurs.
iii) Discharge process: At a fixed point where the leading edge of the flute and the edge
of the discharge port co-inside, compression ceases and the air is discharged into the
delivery line, until the flute volume has been reduced to zero.

3 Attempt Any THREE of the following: 12

a) Compare gear pump and vane pump on the basic of:-

Parameters Gear pump Vane pump

Construction Construction Simple in Complex in construction.

construction than vane
01 mark
Pump.
each
Speed 1200 to 2500 RPM 1200 to 1800 RPM

Application Pumping high viscosity High-pressure hydraulic pumps

fluids such as oil, paints, and in automobiles, including
resins or foodstuffs supercharging, power-steering,
air conditioning, and automatic-

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transmission pumps.

Pressure 35 to 200 Bar 70 to 140 Bar

b) Explain the working of sequence valve with neat sketch.

02 +02

c) Compare meter in and meter out Circuit.

Sr No Meter-IN Meter-OUT
When a pressurized oil flow through When oil flow from pump to the actuator
the circuit it passes through D. C. through D.C. valve it will push the piston in
valve and enters in the flow control the forward direction. The oil from the
1 valve. The opening of the flow control piston rod side is pushed through the outlet Any 04
valve is reduced to decrease the oil of B of D.A. Cylinder through the return points
flow rate. Control of piston is achieved line
only in advance stroke.
(01 mark
each)
Flow control valve ‘F’ is placed in Flow control valve ‘F’ is placed in return
2
pressure line line

Give best result when used in higher The actuator movement is very stable
3
pressure systems.

Relatively small friction to face by Heat generated due to throttling at flow

4
piston which increases life of piston control valve is given to the oil tank.

Suitable for very low piton rod speeds Provides positive speed control of the
5
cylinder

Throttling of fluid takes place which Since both sides of piston there is pressure,
6 heats the oil and hot oil into admitted there is possibility of higher friction.
into cylinder

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The circuit is used where finer speed This circuit is used where very stable
7
control is required. movements of actuators are needed.

Used in - Surface grinders, Welders, Used in - Drilling, boring, reaming and

8
Milling Machines tapping operations

d) A machine holds the steel sheet and then punches a hole. The sheet is released when
the punch goes back. Suggest and draw the suitable circuit for this situation.

Suggested circuit : - Sequencing Circuit

01 mark
for
circuit
name

03 marks
circuit
diagram

4 Attempt any THREE of the following: 12

a) Explain with neat sketch working 3/2 DCV. 02 + 02

Normal Position

Actuated Position

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Working:-
Push button operated spring return type 3/2 sliding spool valve. It has spring loaded spool
inside the valve body.
In actuated position there is connection from port 1 to port 2,oil flows from pump to SA
cylinder & hence SAC extends.
In normal position there is connection from Port 2 to Port 3 ,Oil flows from SA cylinder to
tank & SAC Retracts. Here inlet port 1 is closed.

b) Give Classification of control Valve. Any 04

1) According to function. types
a) Pressure control Valve.
i) Pressure relief valve. (1 mark
ii) Pressure reducing valve. each)
iii) Unloading Valve.
b) Direction control valve
i) 2 x 2 DCV
ii) 3 x 2 DCV
iii) 4 x 2 DCV
iv) 4 x 3 DCV
c) Flow Control valve.
i) Fixed displacement FCV
ii) Variable displacement FCV
iii) Pressure compensated FCV
2) According to method of actuation
a) Manual operated
i) Push button operated.
ii) Hand lever operated.
iii) Pedal operated.
b) Pilot operated
i) Single Pilot operated.
ii) Double Pilot operated.
3) According to Construction.
a) Poppet type.
i) Ball type.
ii) Conical Poppet type.
b) Spool type
i) Sliding spool type.
ii) Rotary spool type.

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c) Explain flexible hose. State its material and application

01 mark

01 mark

Explanation:-Flexible hose pipes are extensively employed in hydraulic systems and

pneumatic systems. As they are easy to accommodate and to connect with in the 01 mark
available space. These pipes are made of elastic material and can be bent easily. Flexible
pipe is made of several layers with metal wire braiding between them. Those metal wire 01 mark
reinforcement increases the strength of the pipe
Material:- Nylon braided hoses, Steel wire reinforced rubber hoses, poly-urethene tubes,
poly-ethylene tubes.
Application:-Convey the hydraulic oil. It is used to transfer liquids under high pressure in
the oil industry.

Pneumatic circuit using Sequence valve

d)

02 + 02

Explanation :- Pressure dependent sequencing circuit :

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The circuit is used for drilling a hole in work piece.
The sequence operation is
a) Clamping of work piece
b) Drilling
c) Decamping and drill taken out from hole.
The DC valve takes centre position (no 3.) no compressed air supplied to either of cylinder
C1 or C2. Now undrilled work piece is kept on fixture seat. The compressed air from
compressor is going to vent via DC valve so no movement of cylinder C1 or C2.
Now compressed air start supplying directly to C2 and through sequence valve to C1
When compressed oil enters through port A2 of cylinder C2 piston will advance and
immediately clamps the work piece.
At the same time compressed air flow towards port A1 of cylinder C1 but through the
sequence valve.
Some higher pressure is set at pressure relief valve of sequence valve when the pressure of
flowing air reaches this set value the sequence valve opens and air enters through port A1
into cylinder C1 due to this piston advances comes down so that drilling starts.
When operator again operate foot lever of DC valve it takes position 2 and both piston
retracts and work piece de-clamps and drill comes out of drilled hole.

Hydraulic circuit of milling machine & explain its working.

e)

02 + 02

Explanation: - Hydraulic circuit for milling machine is comparatively different from other circuits.
Table movement of milling machine is required to be adjustable for different feeds for different
type of work. Therefore for both strokes of the cylinder, on both ends of cylinder flow control

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valves are used. Another feature of this circuit is that there are two pumps
1. Main pump – low pressure high discharge
2. Booster pump - high pressure low discharge
The function of booster pump is to boost the hydraulic pressure to a higher level than given by
main pump. Reason behind using this type is to save power as well as use of high pressure high
discharge pump is avoided. 4/3 DCV used manually operated stroke length of cylinder is
adjustable through limit switch. In centre position of 4/3 DCV all the ports are close therefore,
total hydraulic system is lock. In position (I) pump flow is given to cylinder blank end and
extension starts and oil from rod end is discharge to tank In (II) position, pump flow diverted to
rod end for retraction and blank end side flow pass to tank.
Attempt any TWO of the following:
5 12

a) Draw and Explain two pump unloading circuit

02 +04

Importance of circuit:

 High-low system of pump consists of two pumps in which one pump has high flow
rate and other has low flow rate. They are used to save the system power. Both
pumps can be used simultaneously depending upon system requirement or high
flow rate is diverted through unloading valve if needed in the system.
 It is useful when combination of rapid and slow movement required in the circuit.
Explanation of Circuit :
 The circuits has low pressure (LP) and high pressure (HP) pumps are provided as
shown in Fig.
 When rapid movement of the punch is required, both LP and HP supply the oil so
that the piston retraction will be faster compared to advanced cutting stroke.
 Initially slow movement is required when punch starts movement towards the
workpiece, the flow of HP is diverted through unloading valve and only LP will
supply the oil to the actuator.
 When punch reaches near the workpiece, high force is needed for press
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operations, HP supply will be started to combine with LP and high pressure is
generated for performing press operation.
Applications :
Hydraulic press machines.

Two faults detected in Pneumatic circuit and its causes and remedies
b) 1)Fault: No pressure in the pressure side. 1 mark
each for
Causes: Air leakage, pressure gauge faulty
fault,
Remedies: Check pressure gauge working properly and repair it. causes
and
2)Fault: Service unit (FRL) failed to work properly
remedies
Causes: Filter stopped, Pressure regulator reads differently, Absence of oil drops in
Any two
lubricator
Remedies: Clean filter to remove clogging, Set regulator properly, Fill up oil container of
lubricator
3) Fault: Operating trouble of compressor
Causes: Dirt in suction filter, Worn out piston rings
Remedies: clean the filter, replace Worn out piston rings

Situations in which following Centre positions of DC valves are used

c)
1) All ports open (Open centre position) :
 In this position, all ports are connected internally. Here oil flows through all Each
ports P, A, B and R. position
3 marks
 The open centre condition is used to unloads the pump and allows the
for
actuator to stop or float. explanati
 It causes little shock during changeover to other conditions of valve. Fixed on
volume pumps are used for this centre condition.
With
symbol

2) Tandem Centre position :

 This center is very common in applications like the simple press circuit, to
allow the pump's flow to go straight to the tank, rather than forcing it over the
relief valve.
 In this position, Port P of pump is connected to port R to divert flow of pump
to the tank. Port A and B of actuator are closed.
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 It will unload the pump to the reservoir while blocking the cylinder ports A
and B. Fixed volume pumps are used for this centre condition.

6 Attempt any TWO of the following: 12

Valve selection for delay the controlling action :

Time Delay valve is used for delay the controlling action by sometime after the
a) actuation od Dc valve.

Selection
: 2 marks

Figure 2
marks

Working
2 marks

Working:
 Initially when compressed air is supplied to the port P of the valve, it is prevented
from flowing to port A from port P, as the spool blocks this port A.
 When air is allowed to enter through pilot port Z, it flows through needle
operated flow control valve where its flow can be regulated.
 The air then enters in the air chamber where pressure starts building here. when
sufficient amount of pressure is generated, it pushes the spool of 3/2 D.C. valve.
 Now the opening port P is get connected port A and port R is closed. Air can flow
easily from port P to port A to actuate the actuator.
 The time required to build up the pressure in the reservoir is the amount of time
delay of the time delay valve.
The time delay can be set by using needle adjustment screw to control flow rate of air.

b) Selection of an actuator for longer stroke length:

 Telescopic cylinder is used for longer stroke length and can be accommodated in
less space after retraction.
 The cylinders are arranged in a short envelope hence space required is less. Selection
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: 2 marks

Figure 2
marks

Working
2 marks

Working :
 When pressurized oil enters in the main cylinder 1 it will push the cylinder 2 in the
upward direction when sufficient oil pressure is generated.
 Now the cylinder 2 is completely lifted and oil will enter into the inlet of cylinder 2.
 The oil will flow in the cylinder 2 and push the piston in upward direction. It will
raise the piston for stroke length of cylinder 2.
 In this manner, the total length of stroke through which the load is lifted is (L 1 +
L2).
 It is suitable where less space is available for mounting of actuator.
 Used in equipment like tilting of truck dump bodies, fork lift trucks, hydraulic
cranes.

Difference Between Hydraulic and Pneumatic system

Sr. No. Point Hydraulic Pneumatic
c) 1. Medium used Hydraulic system uses Oil Pneumatic system uses Air

2. Storage of Reservoir is required to Air is free from atmosphere

medium store oil hence storage of input medium
not required

3. Storage device Reservoir of suitable Air receiver to store Any 06

capacity in liters compressed air under pressure points
(01 mark
4. Reuse Re circulated again to Freely available hence not
each)
save cost necessary to recirculate.

5. Cost of medium Hydraulic oil is Costly Freely available from nature.

But cost of compression

6. Power device Pump is used to increase Compressor is used to increase

pressure of an oil pressure of an air

7. Return lines Required for recirculation Not required direct exhausted to

atmosphere

8. Lubrication Self lubricated as oil is Separate lubricator needed for

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having lubrication smooth working of system
characteristics.

9 Operating 300 to 700 bar Limited to 10 bar

pressure

10 Application Heavy equipments cranes, Hand tools, press machines,

lifts, farm equipments, foundry machines, small cranes,
JCB bulldozer, etc etc

-------END----

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MODEL ANS S22

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SUMMER – 2022 EXAMINATION
Subject Name: Industrial Hydraulics and Pneumatics Model Answer Subject Code: 22655
Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in the model answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
XXXX
understanding level of the candidate.
X
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not applicable for
subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The figures
drawn by candidate and model answer may vary. The examiner may give credit for any equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values may vary and
there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgment on part of examiner of relevant answer based on
candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual (English +
Marathi) medium is introduced at first year of AICTE diploma Programme from academic year 2021-2022. Hence if
the students in first year (first and second semesters) write answers in Marathi or bilingual language (English
+Marathi), the Examiner shall consider the same and assess the answer based on matching of concepts with
model answer.

Q. Sub Answer Marking

No. Q. Scheme
N.

01 a Advantages –

1. Hydraulic systems are easy to control and accurate 01 mark for

2. Hydraulic systems are simpler and easier to maintain any two
3. Hydraulic systems can deliver constant torque or force regardless of speed advantages
changes.
4. Easy to spot leakages of a hydraulic system.
5. Provision of automatic lubrication.
6. A large amount of power can be transmitted through the hydraulic system using
small flexible hoses and tubes.
7. Force multiplication is possible with these systems.
8. Minimize undesirable noises.
9. Easy to repair major machines in Hydraulics like Hydraulic Rams, direction
control valves, gear pumps, and motors.
Disadvantages –
1. Leakage of these fluids will create environmental problems and safety issues.
2. Contaminants present in the hydraulic fluid will damage the system
performance and productivity. Hence, it requires continuous filtration.
3. Wrong selection of hydraulic fluid for a system will damage the components.
01 mark for
4. Proper maintenance is required. any two
disadvantages
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5. Maintenance cost is high.

01 b Definition of Viscosity Index:

The viscosity index (VI) is an arbitrary, unit-less measure of a fluid's change in viscosity 02
relative to temperature change. It is mostly used to characterize the viscosity-
temperature behavior of lubricating oils.

OR

It is calculated number which describes the change in viscosity with respect to

temperature.
01 c 02

Correct
symbol

Q. Sub Answer Marking

No. Q. N. Scheme

01 d Fixed Displacement Pumps 01 mark

for two
1. Gear Pump names
2. Bent Axis Piston Pump

Variable Displacement Pumps 01 mark

1. Vane Pump for two
names
2. Axial Piston Pump

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Q. Sub Answer Marking
No. Q. N. Scheme

01 e

01 mark
graph

01 mark

labeling

Q. Sub Answer Marking Scheme

No. Q. N.

01 f 1. Closed Centre

Any two
positions 02
marks

2. Open centre position :

3. Tandem centre position :

4.Float Centre

5.Regeneartive Centre

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Q. Sub Answer Marking Scheme

No. Q. N.

01 g Cross sectional diagram of shuttle valve

01 Mark

sketch 01 Mark
labeling

Q. Sub Answer Marking Scheme

No. Q. N.

02 a Sketch of Unbalanced Vane pump:

(Consider appropriate sketch showing construction)

02 marks –

01 Mark

sketch 01 Mark
labeling

Working :

 When the rotor rotates, the centrifugal force pushes the vanes out against
the surface of the cam ring.
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 The vanes divide the space between the rotor and the cam ring into a series 02 marks –
of small chambers. Explanation
 During the first half of the rotor rotation, the volume of these chambers stepwise
increases, thereby causing a reduction of pressure. This is the suction
process, which causes the fluid to flow through the inlet port.
 During the second half of rotor rotation, the cam ring pushes the vanes back
into the slots and the trapped volume is reduced. This positively ejects the
trapped fluid through the outlet port.
02 b Suitable actuator selection :
We can use or suggest Telescopic cylinder in the given condition described in
question statement
Sketch: (Consider appropriate sketch showing construction) 02 marks –
diagram with
correct labeling
and selection

Explanation:
02 marks –
 A telescopic cylinder (shown in Fig.) is used when a long stroke length and a explanation
short retracted length are required. The telescopic cylinder extends in stages,
each stage consisting of a sleeve that fits inside the previous stage.
 They generally consist of a nest of tubes and operate on the displacement
principle. The tubes are supported by bearing rings, the innermost (rear) set
of which have grooves or channels to allow fluid flow.
 The front bearing assembly on each section includes seals and wiper rings.
Stop rings limit the movement of each section, thus preventing separation.
When the cylinder extends, all the sections move together until the outer
section is prevented from further extension by its stop ring.
 The remaining sections continue out-stroking until the second outermost
section reaches the limit of its stroke; this process continues until all sections
are extended, the innermost one being the last of all.

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02 c Methods of Actuation of DC Valves:

i) Lever operated :In this valve, the angular movement of lever is transmitted to move the
spool.It is commonly used for JCB and material handling equipments.

(ii)Push button operated :It is push type and spring return similar to electrical switch.
02 Marks for
each method

01 mark for
symbol/sketch

1 mark
(iii) Pedal operated :It is foot operated similar to brake of 4 wheeler and used when statement
hands of the operator
(any two
need to be kept free. methods)

(iv) Roller operated :The roller is pressed to actuate the spool with the help of cam.

(v) Solenoid (Electrical actuation) :It uses a solenoid to operate the valve spool. The
solenoid may be A. C. or D. C.It can be coupled with hydraulic/pneumatic actuation.

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Q. Sub Answer Marking
No. Q. Scheme
N.

02 d Schematic diagram of a pressure and temperature compensated flow-control valve is

shown in Fig. (Consider appropriate sketch showing construction)

02 marks
for diagram

Explanation:

 Its operation is essentially same as the restrictor type, pressure compensated flow
control valve in association with a throttle type temperature compensating device.
In the compensatory spool, the pressure is sensed to the bottom of the spool
through a passage drilled in its body, instead of having a separate sensing passage.
 In order to attain balance position, the compensatory spool moves and adjusts the
area of metering orifice. This gives necessary pressure compensation.
 Also instead of using the usual throttling arrangement, a cup shaped device with
“V” notches is used for better control on flow rate. This cup is held by a small
spring against the shoulder of an aluminum alloy rod which extends through the
cup into the oil flow. It is set for a particular flow rate.
 As temperature of oil rises, the oil becomes a little thinner and tend to flow faster 02 marks
through. for
explanation
 However, the increased temperature also causes the Aluminum rod to expand and
close the throttle opening to compensate for the change in oil viscosity. Thus even
with the thinner oil, the flow rate stays essentially the same.
 A check valve is frequently incorporated to allow relatively unrestricted reverse
flow.

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Q. Sub Answer Marking
No. Q. N. Scheme

03 a Time delay valve: 02 marks

for
diagram

With
correct
labeling

Working:

 It is simply a 3/2 direction control valve, which is impulse operated from one side.
Time delaying is achieved by delaying the impulse actuation. The valve has an in-
built air reservoir and in-built non-return flow control valve.

 When impulse is applied to port “P1” for valve actuation, the air passes through
needle control valve, which controls the rate of flow, further the valve spool is not 02 marks
actuated until the air reservoir is filled completely and pressure is built-up. (This for
working
time difference between impulse application at “P 1” and actual spool actuation is
the “delay”, which is adjustable through needle valve).

 The time delay function is obtained by controlling the air flow rate to or from the
reservoir by using the throttle valve. Adjustment of throttle valve permits fine
control of time delay between minimum and maximum times.

03 b Pressure reducing valve:

Sketch : (Consider appropriate sketch showing construction)

02 marks
for
diagram

With
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correct
labeling

02 marks
for
construct
ion
Construction:

i. This type of valve (which is normally open) is used to maintain reduced pressures in
specified locations of hydraulic systems.
ii. It is actuated by downstream pressure and tends to close as this pressure reaches
the valve setting.
iii. A pressure-reducing valve uses a spring-loaded spool to control the downstream
pressure. If the downstream pressure is below the valve setting, the fluid flows freely
from the inlet to the outlet.
iv. There is an internal passageway from the outlet which transmits outlet pressure to
the spool end opposite the spring.
v. If the valve closes completely, leakage past the spool causes downstream pressure to
build up above the valve setting, to prevent this a continuous bleed to the tank is
permitted via a separate drain line to the tank.
vi. This valve is often equipped with a check valve for reverse free flow.
03 c Spring –loaded accumulator: (Consider appropriate sketch showing construction) 02 marks
Sketch: for
diagram

With
labeling

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Construction :

i. A spring loaded accumulator has a cylinder body, movable piston and a spring. The 02 marks
for
springs draw a force to the piston, producing into a liquid pressure.
construct
ii. As the fluid is pumped into the spring loaded accumulator, pressure in the ion
accumulator is made up of the compression rate of the spring. Some of the
accumulators of them kind, spring pressure can be wide spread by the means of a
screw adjustment.
iii. Spring loaded accumulators are more flexible than the weight loaded ones. They are
smaller and can be mounted in any position.
03 d Diagram of lubricator used in Pneumatic system:(Consider appropriate sketch showing
construction)

03 marks
for neat
diagram

01 mark
for
labeling

03 e Classification of compressor: 02 marks

for
classifica
tion

Applications of Compressors:
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1) Rotary screw air compressors: Large-scale jobs and industrial settings that
require continuous airflow
2) Reciprocating compressors : Home and small-scale construction projects 02 marks
3) Axial air compressors: Aerospace applications and high-speed engines for ships for
4) Centrifugal air compressors: Large-scale steel and chemical manufacturing plants applicati
ons

Q. Sub Answer Marking

No. Q. N. Scheme

04 a Difference between pressure relief valve and sequence valve:

Point of comparison Pressure relief valve Sequence valve

Marks

02

1.Symbol

2.Outlet port Connected to tank Connected to application 01

3.Pilot connection Present Present 01

01
4.Drain Absent Present
01
5.Application to protect the system to move actuators in a
from excess pressure sequence for e.g. Drilling,
punching etc

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Q. Sub Answer Marking

No. Q. Scheme
N.

4 b Hydraulic circuit used in shaping machine:

04 marks
for figure

With
labeling

OR

02marks
for
explanation

Explanation:

1) Forward stroke: As pump is supplying oil to DA cylinder through the DC valve and
Downloaded
through the port B. Hence piston will moveFrom
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right to left with force and this is a
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cutting stroke. At the end of the stroke ‘stroke changing lever’ will touch to the
adjustable dog S1.

2) Return stroke: When lever touches to adjustable dog (stopper) S1, then spool shifts
right and flow directions in DC valve change as shown. Now oil is entering through the
port A of DA cylinder and piston will move from left to right. During this stroke tool post
slightly lifts and hinged and no question of metal cutting. Again the lever is stopped by S2
and the cycle is repeated.

Q. Su Answer Marking
No b Scheme
. Q.
N.

04 c

Any One
Circuit
Diagram -
04 marks

OR

Explanatio
n – 02
marks

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Parallel Connection :

Two cylinders are connected in parallel as shown in the circuit diagram. Hydraulic oil from
4/3 DCV is supplied to blank end of both the cylinders (F1 & F2). This will result into
simultaneous upward movement of both the cylinders while oil from rod end of both the
cylinders will return to the tank through 4/3 DCV.

OR

Series Connection :

Two cylinders are connected in a series as shown in the circuit diagram. Hydraulic oil from
4/3 DCV is supplied to blank end of the cylinder 1 (F1) while oil from rod end of the cylinder 1
enters the blank end of cylinder 2 (F2). Oil from rod end of cylinder 2 will return to the tank
through 4/3 DCV. This will result into simultaneous upward movement of both the cylinders.

Q. Su Answer Marking
No b Scheme
. Q.
N.

05 a I) Pneumatic circuit using Roller operated and Pilot operated DC valves

Diagram –
I

03 marks

With
labeling

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ii) Solenoid operated DC valve and limit
switches

Diagram –
II

03 marks

With
labeling

05 b Pneumatic circuit for Speed control of Air motor :Note: It is not mentioned Uni directional or
Bi directional motor in the question therefore any circuit can be considered out of both)
Diagram -
Speed control of Uni-directional air motor 03 marks

Explanation of circuit : Explanatio

n – 03
The flow control valve is placed before inlet of the air motor, so that flow of compressed marks
air can be regulated, before entering in the From
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1.Slow speed :
The compressed air from port P to port A is allowed to enter in the flow control valve
where the flow area is decreased by partially closing the flow control valve. The reduced
air flow will enter in the motor through inlet A.
The motor will rotate at slow speed as less quantity is available for running the air motor.
2.Fast speed :
When flow control valve is fully opened to increase the flow area, more quantity of air is
allowed to pass through flow control valve.
The increased quantity of air will enter in the motor and rotate it with high speed.
OR
Speed control of Bi-directional air motor Circuit :

Explanation of circuit :
1. Slow speed :

Compressed air is passed through D.C. Valve from port P to port A. It will enter in the
FCV1 where flow area of the FCV1 is reduced by partially closing the valve.
Hence, small quantity of air will enter in the air motor through inlet A. It will rotate the
motor at slow speed.
2. Fast speed :
Similarly, when flow area of the FCV1 is increased by fully opening the valve, it will supply
full quantity of compressed air to the air motor through inlet A.
As large quantity is supplied it will rotate the motor at high speed. We can control the
speed in another direction using FCV2 and second position of D.C. Valve.
Hence by varying the flow quantity of air we can change the speed of bi-directional
motor.

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Q. Sub Answer Marking
No. Q. Scheme
N.

05 c Internal Gear type hydraulic motor:

Diagram
with
labeling -
03 marks

Explanation: Explanatio
It consisting internal gear(ring gear), External gear and cresent or spacer enclosed in a closed n – 03
housing. marks
As shown in figure the external gear teeth are meshes with internal gear.
As the pressurized hydraulic oil enter in to the casing due to pressure force ring gear is
rotated it results in rotation of external gear and torque will generated coupled with shaft of
external gear.
Q. Sub Answer Marking
No. Q. Scheme
N.

06 a

Any two
names &
I. FRL Unit symbols -
02 marks

II. Air Receiver

III. Shuttle Valve

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IV. AND Valve

V. Compressor

02marks

VI. Muffler :

ii) Cross Section of Hose Pipe

(a) Cross section of hose (b) Construction of hose showing layers

OR

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Q. Sub Answer Marking
No. Q. Scheme
N.

06 b Common faults in Hydraulic and Pneumatics system

Any four -
Common Faults Remedies 04 marks
Flow control valve incorrectly adjusted Readjust the valve.
Damaged cylinder or seal Replace cylinder or seal.
System leaks Fix leaks.
Replace regulator or
Damaged or incorrectly adjusted
readjust rating asshown in
pressure regulator valve
drawing.
Directional or other valve open due to dirtor Locate damaged part and clean
failed pilot circuit or replace it.
Electric failure Fix electric failure
Make proper alignment
Misalignment or worn out parts
Replace worn out parts
Defective or worn out actuator Repair or replace actuator
06 c

Diagram -
02 marks

explanatio
n – 01
marks

applicatio
n – 01
marks

By using the shuttle valve, more than one switch can be operated on a single machine for
safety, and each switch can be placed at any suitable location.

This application is normally used with heavy industrial machinery.

Applications 1 Winch brake circuit

2 Air pilot control

3 Standby and emergency systems

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Q. Sub Answer Marking
No. Q. Scheme
N.

06 d

Diagram -
03 marks

Names of
parts 01
mark

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MODEL ANS W23

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WINTER – 2023 EXAMINATION

-
Subject Name: Industrial Hydraulics and Pneumatics Subject Code:
22655
Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in the model answer
scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not
applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The
figures drawn by candidate and model answer may vary. The examiner may give credit for any equivalent
figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values
may vary and there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer
based on candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent
concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual
(English + Marathi) medium is introduced at first year of AICTE diploma Programme from academic year
2021-2022. Hence if the students write answers in Marathi or bilingual language (English +Marathi), the
Examiner shall consider the same and assess the answer based on matching of concepts with model
answer.

Q. Sub Answer Marking

No. Q. Scheme
N.

1 Attempt any FIVE of the following: (2x5=10)

a) Compare Hydraulic and Pneumatic system
Ans: Any four
Sr. Point Hydraulic Pneumatic points – 2
No. marks
1. Medium Hydraulic system uses Oil Pneumatic system uses uses
used Air
2. Storage of Reservoir is required to Air is free from atmosphere
medium store oil hence storage of input
medium not required
3. Storage Reservoir of suitable Air receiver to store
device capacity in liters compressed air under
pressure
4. Reuse Re circulated again to save Freely available hence not
cost necessary to recirculate.
5. Cost of Hydraulic oil is Costly Freely available from nature.
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medium But cost of compression
6. Power device Pump is used to increase Compressor is used to
pressure of an oil increase pressure of an air
7. Return lines Required for recirculation Not required direct exhausted
to atmosphere
8. Lubrication Self lubricated as oil is Separate lubricator needed for
having lubrication smooth working of system
characteristics.
9 Operating 300 to 700 bar Limited to 10 bar
pressure
10 Application Heavy equipments cranes, Hand tools, press machines,
lifts, farm equipments, JCB foundry machines, small
bulldozer, etc cranes, etc
b) I.S. Symbols of 1 mark –
each for
i) Dead weight Accumulator ii) Unloading Valve
correct
symbol

C) Low pressure Hydraulic Pump: 1 mark

Fixed delivery Vane pump: pressure 125 – 175 bar each –for
Variable delivery vane pump : 75 to 125 bar type of
Screw Pump : 60 to 175 bar pump
High pressure Hydraulic Pump:
Bent axis piston pump : 700 bar
Radial piston Pump: up to 1000 bar
d) Applications of Double acting Cylinder : 1 mark
each - for
1. Movement of table of Milling machine, Surface grinding machine
application
2.Tool movement of shaper Machine, Ram of hydraulic press machine
3.Movement of JCB arm, Tractor Trolley lifting mechanism
Applications of Motor :
1. Pneumatic motor: Pneumatic Hand tools like grinder, nut runner
2.Hydraulic motor: Movement of large mixer, Cable winding mechanism
3. Marine winches, rudders, construction equipment, high power industrial machines.
e) Difference between Counter balance and Unloading valve 1 mark
each - for
Point Counter balance valve Unloading valve two
Function It is providing counter (opposite) It is used to unload the oil energy differences
force of oil to prevent rapid falling at a low pressure to save energy,
(balance) of heavy load due to
gravity or overrunning.
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Principle Counter Balance Valve is basically a This unloading valve is generally
relief valve but it is used to set up a located before the pressure relief
back pressure in a circuit to prevent valve helps to reduce heat energy
load from falling. to a great extent
Construction It mainly consists of sliding spool It is spool operated valve which is
operated with the help of spring,
actuated through external pilot
internal pilot line and check valve
line and unloads the pressurised oil
from pump.

f) Use of FRL unit : 1 mark - for

application
FRL unit is combined box set made up of a filter, regulator and lubricator
FRL
 Filter (F) –It is used to separate out contaminants like dust, dirt particles from the
compressed air
 Regulator (R) – In pneumatic system the pressure of compressed air may not
stable
1 mark - for
due to
application
possibility of line fluctuation. Hence there is a need to maintain and regulate the air of time
delay valve
pressure. This function is performing by regulator.

 Lubricator (L) –To reduce friction of Sliding components like spool, a pneumatic
cylinder, lubricating oil particles are added in the compressed air with the help of
lubricator.
Use of Time delay valve:
 As name indicates, this valve is used to initiate a delayed signal in the pneumatic system.
 It is useful in sequencing circuits to actuate the cylinder or motor with certain time delay.
g) Common faults in Hydraulic Circuits 2 marks -
Fault 1 : Excessive noise in pump for any two
common
Causes Remedial action
faults
Air in fluid medium Check leakage at inlet Pipe and make joints leak
proof
Misalignment/worn out Make proper alignment Replace and overhand worn
parts out parts

Fault 2 : Overheating
Causes Remedial action
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Damaged pump Replace damaged pump if can’t repair
Misalignment, worn out Make proper alignment, Replace worn out parts
parts
Fault 3 : No pump delivery
Causes Remedial action
Wrong rotation of pump Should be corrected
Oil viscosity too high Use correct grade of oil.
2 Attempt any THREE of the following: (3x4=12)

a) Safety precautions required for handling hydraulic and Pneumatic system: 4 marks -
for any
General safety precautions during use/maintenance of hydraulic system are
eight
1) Never begin work on hydraulic system until fully trained. precautions

2) Never begin work on hydraulic system without using a risk assessment.

3) Carefully review the instructional manual of equipment before beginning of work.
4) Use all required safety equipment during use/maintenance work.
5) Never try to repair components without improper knowledge.

6) De-pressurise the system before start of work. Shut down/local isolation may be taken if
required.

7) Do not use base hands to check the hydraulic leakage. Any fluid leakage through pin
hole can injected into the skin. Use card board/wooden piece to check leakage.

8) Wear appropriate personal protective equipments (PPE) like safety glasses, hearing
protection devices, gloves, eye shield, shoes, etc.

9) Ensure all connection are tight and secure and hold the open end of hose firmly to avoid
uncontrolled whipping of the rose.
10) Never use compressed air to transfer flammable liquids.
11) Use suitable safety devices, instructional manual while doing maintenance and repair.

b) Construction and Working of Gear type motor

Construction : It mainly consists of : 2 marks for
(a) Gear pair: Two meshing gears are mounted with one gear on the driving shaft while labeled
meshing gear is mounted on driven shaft. sketch
(b) Casing: It is the outer body of the motor which encloses gear pair and passages for 2 marks for
inlet and outlet ports. Explanation
(c) Inlet and outlet ports: The oil is allowed to enter through inlet port and drain out
through the outlet port.
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Construction of gear motor

Working :
 When pressurised oil enters through the inlet port it exerts oil pressure on the gear
teeths.
 As the casing inside surface and gear pair are closely fitted, the oil pressure acts on
the one side of one tooth on the gear located near the inlet port.
 This will cause hydraulic imbalance and it push the gear tooth to develop torque. The
larger the gear tooth or higher the pressure, more is the torque developed.
 This action continued to produce rotary motion of the shaft. The oil used has low
pressure and of no use hence drained through the outlet port.

c) Two applications of pressure control valves: 4 marks for

1. To relief the excessive pressure if oil pressure is greater than working pressure of the any two
applications
system :
with
Explanation

2. Regulating and reducing pressure in certain portions of the circuit :

When actuator 1 requires pressure of 30 bar while actuator is operating at pressure of 15
bar. In this case, the pressure of the oil is to be reduced from 30 bar to 15 bar. This
function is performed by pressure reducing valve.

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3. To achieve sequential operation of actuators in circuit with pressure control:

When the numbers of actuators are to be operated one after another in a sequence, with
the help of pressure control, sequence valve of pressure control is used.

d)
Double acting Reciprocation compressor
2 marks for
Construction of two stage reciprocating compressor : labeled
 The Fig. shows outer construction of reciprocating compressor. It includes following sketch
main parts :
2 marks for
(a) Air receiver or tank : It stores compressed air. It is fitted with various accessories.
Explanation
(b) First stage cylinder : The cylinder is mounted along V type of arrangement .
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(c) Second stage cylinder : This cylinder is mounted along with first stage cylinder in
radial manner.
(d) Intercooler : It is fitted between first stage cylinder and second stage cylinder.
(e) Pressure gauge : It is fitted on air receiver tank to indicate the pressure of
compressed air stored in the tank.
(f) Electric motor : It is the prime mover to run the compressor. The motor shaft is
connected by belt drive to the compressor shaft.

Working :

When the starting of the electric motor, the crank rotates and the piston in the first
stage cylinder sucks the atmospheric air through the suction filter and inlet valve.

On further rotation of the crank, the piston reverses and it compresses the air. The
compressed air forces the outlet valve to open.

Then it enters in the intercooler to the second stage cylinder forcing open its inlet
valve. The air is further compressed in this cylinder to the desired pressure. It is then
fed to the air receiver tank through the condenser on compression through the outlet
valve.

The first-stage cylinder is called Low Pressure Cylinder (LP). It can develop pressure up
to 5 bar. The second stage cylinder is called as High Pressure Cylinder (HP). It can
develop further pressure up to 10-12 bar. Multistage compressors can produce
2
discharge pressure up to 300 kg/cm

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Q. Sub Answer Marking
No. Q. Scheme
N.

3 Attempt ANY THREE of Following: (3x4=12)

a) Enlist four Fault and remedies for Hydraulic Pump

S. N. Fault Caused Remedies Any four
1 Pump 1) Cavitation Any or all of the following: causes
noisy  Replace dirty filters. and
 Wash strainers. Remedies
 Clean the clogged inlet line. (Column
 Clean the reservoir breather vent. no.3and
 Change the system fluid. 4)
 Change to proper pump drive motor speed.
 Overhaul or replace the pump. 1 mark
 Check fluid temperature for each
2) Air in fluid Any or all of the following: causes
 Tighten leaky inlet connections. and
 Fill the reservoir to proper level. Remedies
 Bleed air from the system.
 Replace the pump shaft seal.
3) Coupling All of the following:
misaligned  Align unit.
 Check the condition of seals, bearings and
couplings.
4) Pump worn or  Overhaul or replace defective parts
damaged
2 Pump 5) Fluid heated See symptom “fluid heated”
heated
6) Excessive load All of the following:
 Align unit.
 Check the condition of seals, bearings and
couplings.
 Locate and correct mechanical binding.
 Check for workload in excess of circuit
design
7) Pump worn or Overhaul or replace defective parts
damaged

Explain with neat sketch pressure compensated flow control valve with neat sketch.
b

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2 marks
for
labeled
sketch

2 marks
for
Explanati
on

Pressure-compensated flow-control valves overcome the difficulty caused by non-pressure

compensated valves by changing the size of the orifice in relation to the changes in the
system pressure. This is accomplished through a spring-loaded compensators spool that
reduces the size of the orifice when pressure drop increases. Once the valve set, the
pressure compensator acts to keep the pressure drop nearly constant. It works on a kind of
feedback mechanism from the outlet pressure. This keeps the low through the orifice
nearly constant. In the static condition, the hydraulic forces hold the compensator spool in
balance, but the bias spring forces it to the far right, thus holding the compensator orifice
fully open. In the flow condition, any pressure drop less than the bias spring force does not
affect the fully open compensator orifice, but any pressure drop greater than the bias
spring force reduces the compensator orifice. Any change in pressure on either side of the
control orifice, without a corresponding pressure change on the opposite side of the
control orifice, moves the compensator spool. Thus, a fixed differential across the control
orifice is maintained at all times. It blocks all flow in excess of the throttle setting. As a
result, flow exceeding the preset amount can be used by other parts of the circuit or return
to the tank via a pressure-relief valve.

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c) Draw Hydraulic circuit for grinding machine and explain working 2 marks
for
labeled
sketch

2 marks
for
Explanati
on

The hydraulic circuit component of the surface grinding machine consist of

1.Double acting hydraulic cylinder
2.Pilot operated direction control valve (DCV)
3.Pilot valves
4.Oil reservoir
5.Pressure relief valve
6.Return line filter

In surface grinder machine, the work-piece is clamped on the machine table. The machine
table is made to reciprocate using a double rod end type DAC. That is the work-piece is
made to reciprocate against a rotating multi-point cutting tool (milling cutter or grinding
wheel).
Thus the cutting tool cuts the metal.
• Continuous reciprocation of ram can be obtained either by using solenoid DCV or by using
pilot-operated DCV. You need limit switches if solenoid DCV is chosen and limit valves if
pilot-operated DCV is chosen.
• In this example, pilot operated DCV and limit valves are used.
• 4/2 double-pilot DCV is used with two limit valves on either end of the piston rod. The
piston rod, while reciprocating, actuates these limit valves, which intern actuates 4/2
DCV. Thus automatic reciprocation of ram is achieved.
• In first position of 4/2 DCV, oil flows from P – A and B – T. Hence the piston extends.
• In second position 4/2 DVC, oil flows from P – B and A – T. Hence the piston retracts.
• Flow control valve is placed in return line to the reservoir, hence it is meter out circuit
with same speed in both strokes.

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d) Holding and drilling of mild steel bar circuit (Sequencing circuit) 1 mark
for
suggestio
n and 03
marks
for
correct
circuit
diagram.

NOTE: Similar answers with sequencing circuit should also be considered.

4 Attempt ANY THREE of Following: (3x4=12)

a) Different center position with sketch. 1 mark

each.

Closed center Open center Tandem Center Float center

b) Explain with neat sketch sequence valve 2 marks
for
labeled
sketch

2 marks
for
Explanati
on

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Sequence valve Symbol

A sequence valve is a pressure-control valve that is used to force two actuators to operate in
sequence. They are similar to pressure-relief valves. Schematic diagram of sequence valve is shown
in Fig.

Instead of sending flow back to the tank, a sequence valve allows flow to a branch circuit, when a
preset pressure is reached. The check valve allows the sequence valve to be bypassed in the reverse
direction. The component enclosure line indicates that the check valve is an integral part of the
component. The sequence valve has an external drain line; therefore, a line must be connected
from the sequence valve’s drain port to the tank. The symbol for a sequence valve is shown in Fig.

NOTE: Similar answers with slight modification in symbol should also be considered.

c) Any four accessories used in Pneumatic system 1 marks

1) Hoses & Connectors each
Requirement of hoses and hose fittings:
1.It should be flexible sufficiently
2.It should be able to work with maximum system pressure
3.It should be provided with proper end fitting
4.It should be oil & weather resistant
5.While assembling, care should be taken to avoid sharp bends, twists, & tension in the hose.
6.Care should be taken while installation regarding the permissible limits of temperature which the
hose can withstand.
Flexible hoses materials
Hose provide flexible connection for linking two relatively moving machine components.
These are made of
 •Nylon,
 •PVC,
 •Flexible metallic tubes,
 •Elastomeric or rubber tube of reinforced construction.

2) Fittings

 Straight fitting,
 450 elbow fitting or
 900 elbow fitting.

3. Reusable type end fittings: These may be

Straight fitting,
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450 elbow fitting or
900 elbow fitting

4.Quick disconnect couplings: (Quick Release couplings QRC)

Some application require frequent connecting & disconnecting of fluid supply components.
This requirement is fulfilled by a specially designed connector known as Quick disconnecting
coupling.

Note :- Students may write filter ,regulator and Lubricator marks shall be given to these
basic units also
d) For CNC machine door opening and closing circuit ( Automatic) 2 marks
By using limit switches and double solenoid 4/2 DCV, Limit switches : for
Note :- Students may draw different circuit check logically labeled
sketch

2 marks
for
Explanati
on

In first position of 4/2 DCV, fluid flows from P – A and B – T . hence the cylinder extends.
• By the end of extension, the cam fitted to piston rod presses the limit switches to operate this 4/2
DCV.
When a limit switch is pressed, electric current flows to the connected solenoid and hence the spool
of 4/2 DCV shifts to other position.
• The piston rod, while reciprocating, actuates these limit switches, which intern actuates 4/2 DCV.
• Thus automatic reciprocation of ram/Door is achieved

NOTE: Similar answers with slight modification in circuit should also be considered.
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e) Meter in circuit 2 marks

for
labeled
sketch

2 marks
for
Explanati
on

In meter in pneumatic circuit flow control valve with check valve is fitted between DCV and
actuator.

For speed control of actuator during extension stroke, FCV with check valve is fitted on
piston side of the actuator as shown in figure. With a meter-in circuit, fluid enters into the
actuator at a controlled rate.

Pneumatic circuit diagram for meter-in flow-control circuit is as shown in figure. In this
circuits, the rate of flow of compressed air into the cylinder is controlled by flow control
valve.

FCV is placed at inlet of the cylinder. Cap end port “C” is inlet for extension and rod end
port “R” is inlet for retraction. Working: In first position of 4/2 DCV, compressed air flows
from P to A and B to T. this flow is through flow control valve, the flow is controlled and
hence piston extends slowly. In second position 4/2 DCV, compressed air flows P to B and A
to T. this flow is through check valve. This is free flow. Hence the piston retracts at higher
speed, Which is not controlled.
NOTE: Similar answers with slight modification in circuit should also be considered. Logical
thinking should be given waitage.

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Q. Sub Answer Marking

No. Q. N. Scheme
5. Attempt any TWO of the following: (2x6=12)
a)
In a dumping truck needs cylinder of giving longer stroke strength suggest the type of
actuator to be used with justification.

NOTE: Similar answers with slight modification should also be considered. 2 Marks for
fig
For the application mentioned in the above question we can select following actuator:
Telescopic Cylinder

Justification:
Three Rams assembled in each other like
telescope. This arrangement provides relatively
long stroke with good mechanical strength. There
2 Marks for
are two inlet ports through which pressurized
hydraulic oil enters. Port (R) is raising the Justification
cylinder or extending the cylinders while port (L)
is for cylinder lowering. 2 marks for
working.
Working:
1. Raising or extending the cylinders: hydraulic
oil under pressure will enter through port (R).
Space ‘X’ will be filled by oil and Ram 1 will start raising upwards. When its raising stops, the
oil now will start entering through and will occupy space ‘Y’. Due to this Ram 2 will raise.
When raising of Ram 2 stops, the oil will start entering through and will occupy space
‘Z’. This will raise final Ram 3 upwards.2. Lowering the rams: When pressurized oil
will enter through port (L), then Ram 1 will come down. After it’s lowering Ram 2 will
lower and then Ram 3 will lower.

b) Discuss the situation in work-shop shifting CNC machine one place over another place
by using hydraulic lifter suggest type of D.C.V., P.C.V and F.C.V. with justification.
(similar answers should also be considered)
In the situation mentioned above we need to shift the CNC machine from one place to another
place by using hydraulic lifter. Now the weight of the CNC machine is most crucial factor in
deciding the capacity and type of valves used in hydraulic lifter. While shifting this heavy-duty
machine we must also consider the safety of the movement and abrupt/sudden fall of the
machine. We can suggest following control valves in the hydraulic lifter:

Direction Control Valve: Solenoid operated spring return 4X3 DCV

With solenoid operated valve actuation method, we can remotely operate the DCV. Four DCV:
ports of the 4 X 3 DCV gives us the freedom to use various double acting cylinders with
suitable mounting method. The three positionsFrom
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direction in forward or in reverse. The center position of the DCV makes the immediate
stoppage of the movement of the CNC machine.

PCV:
Pressure Control Valve: Counter Balance Valve
It is basically a relief valve but it is used to set up a back pressure in a circuit to prevent 2 Marks
load from falling. They are frequently employed in vertical presses, loaders, lift trucks and
other machines that must maintain a particular position or hold a suspended load. In our
case the load is weight of the CNC machine. In such applications, the counterbalance valve
creates a back pressure to prevent the movement of piston rod of cylinder. FCV:

Flow Control Valve: Variable type flow control valve with checked flow 2 Marks
The flow control valve will regulate the flow of pressurized hydraulic oil in the circuit
ultimately controlling the speed of the movement. This is very helpful while lifting the
CNC machine from the ground from inertia state to the moving state. Also, the speed of the
movement must be controlled from one place to another.
c)
2 Marks
It is required to delay the controlling action by sometime after the actuation of DC valve,
Select the suitable valve for this application and explain its working with neat sketch.
The suitable valve for the application stated in above question will be:
Time Delay Valve

Labeled sketch
Sketch:

2 Marks

Working:
 Time delay valve is a combination valve used to set the operation time as per
the
requirement. The time delay can be increased or decreased by adjusting the flow 2 Marks
through the non-return flow control valve.
 The change invariably increases or decreases the time taken to fill and pilot
actuates the direction control valve.
 Time delay valve is a combination of a pneumatically actuated 3/2 direction
control valve, an air reservoir and a throttle relief valve.
 The time delay function is obtained by controlling the air flow rate to or from
the reservoir by using the throttle valve.
 Adjustment of throttle valve permits fine control of time delay between
minimum and maximum times. In pneumatic time delay valves, typical time
delays in the range 5-30 seconds are possible.

6. Attempt any TWO of the following: (2x6=12)

a)
Draw and explain time delay circuit for Broaching operation.
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Time delay circuit for Broaching Operation:

Explanation:

A push button operated 3/2 D.C. Valve will start the cycle. The normally closed time
delay valve actuates the main impulse valve (pilot operated 4/2 D.C. Valve) at its pilot Sketch:
port Y. The time delay valve can be set for delay for actuation of impulse valve. The time
taken by time delay valve to transmit the signal is the time delay for the forward motion of 3 Marks
the cylinder. When pilot operated 4/2 D.C. Valve in an actuated position it, advances the
cylinder and complete its forward stroke.
Working:

3Marks

NOTE: Similar answers with slight modification in circuit should also be considered with
time delay valve.

There are two hydraulic cylinder which operates in sequence. Forward stroke of first
b) cylinder, take place followed by automatic forward stroke of second cylinder. However,
retraction takes place first in second cylinder followed by the same in first cylinder.
Draw suitable circuit and name all components. Correct
circuit
Second diagram
with
First correct use
of valves

4 Marks

And 2
marks for
labeling

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NOTE: Similar answers with slight modification in circuit should also be considered.

A Hydraulic bending machine can be operated from both the side. Draw pneumatic
c)
circuit which ensures both hands safety of the worker while operating the machine
from any side. (similar two hand operated circuits should also be considered)

Correct
circuit
diagram
with
correct use
of valves

4 Marks

And 2
marks for
labeling

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