Hydraulic Pressure Control

Topics

Pressure Relief Valves

Unloading Valves
Pressure-Reducing Valves
Sequence Valves
Counterbalance Valves
Brake Valves
Pressure –Compensated Pumps
Pressure Control Valve Mounting
Pressure Control Valve Specifications

Lecture 5

Doc Nam
 Pressure Control Valves
Allows for controlling the pressure:
1. Enables control of the output force of a cylinder.

2. Enables control of the output torque of a motor.

Control the maximum pressure level in a hydraulic circuit

Safety
 Pressure Relief Valves
Limit the maximum pressure by providing an alternate path for fluid to flow.

Direct-Acting type – basic, uses a ball or poppet

 Pressure Relief Valves
Pilot operated relief valve – uses a small relief valve and a main relief valve and
operates in two stage process (or compound).

The pilot relief valve opens first, once it receives the maximum pressure the main
relief valve can open.

Generally smaller than direct acting valves and have a wider range of maximum
pressure ratings. They can also be operated remotely using vent port (direct acting)
 MCTE 321
Pressure Relief Valves
Cracking Pressure – The pressure at which the relief valve begins to open. (some
flow through the relief valve). Higher cracking pressure is advantages because
once the relief valve cracks, we lose flow over the relief valve. Lost flow results in
reduced actuator speed and lost power.

Full Flow Pressure – The pressure at which the relief valve is completely open. (all
flow is through the relief valve and is the max pressure of the system)

Pressure Override – The difference between Cracking Pressure and Flow

Pressure.
 Pressure Relief Valves
EX: Compare two types of relief valves operating at 2000 psi and 2250 psi

At 2000 psi
1. Direct Acting: 9gpm is lost across the relied valve, 41 gpm goes to the system so 9/50 X 100 = 18% of the
system flow is lost.
2. Pilot Operated: 0gpm is lost across relief valve, 50 gpm goes to the system so 0/50 X 100 = 0% of the
system flow is lost
 Pressure Relief Valves
EX: Compare two types of relief valves operating at 2000 psi and 2250 psi

At 2250 psi
1. Direct Acting: 25gpm is lost across the relied valve, 25 gpm goes to the system so 25/50 X 100 = 50% of the
system flow is lost.
2. Pilot Operated: 3gpm is lost across relief valve, 47 gpm goes to the system so 3/50 X 100 = 6% of the
system flow is lost
 Pressure Relief Valves
Shifting shock – Occurs when directional control valves are shifted into the closed
position. Shifting the valve closed can cause a pressure spike on the outlet line.

Cross-Over relief valve – Used to prevent shifting shock in motor circuits. Two
pressure relief valves combined into one package and are mounted in parallel 180
degrees to each other.

When the DCV is shifted into neutral, some oil is allowed to flow from outlet to inlet
through the cross-over relief, providing a shock absorbing or cushioning effect.

Two valves are required because the motor is bi-directional and the motor inlet and
outlet will switch depending on the direction of rotation.
 Pressure-Relief Valves
Pressure-Relief Valve’s function is to limit the pressure to a specified
maximum value by diverting pump flow back to the tank. A poppet is
held seated inside the valve by a heavy spring. When the system pressure
reaches a high enough value, the poppet is forced off its seat. This permits
flow through the outlet to the tank as long as this high pressure level is
maintained.
A relief valve is similar to a fuse in an electrical
system. When circuit amperage tries to exceed fuse
amperage, the fuse blows and disables the circuit.

Similarly, in a hydraulic circuit, a relief valve opens and

bypasses fluid when pressure exceeds its setting. The valve
then closes again when pressure falls. Many fixed-volume pump
circuits depend on this bypassing capability during the cycle,
and some even bypass fluid during idle time.
Pressure Control Devices
Relief valves are normally closed valves.
They open when system pressure approaches
the set maximum operating pressure.
The operation of relief valves can be classified
as:

• Direct Operated

• Pilot Operated
Direct-Acting- simple

A direct-acting valve may consist of a poppet or ball, held exposed to system pressure (P) on
one side and opposed by a spring of pre-set force on the other. In a fixed, non-adjustable,
normally closed relief valve, the force exerted by the compression spring exceeds the force
exerted by system pressure acting on the ball or poppet. The spring holds the ball or
poppet tightly seated. A reservoir port on the spring side of the valve returns leakage
fluid to tank.
When system pressure (P) begins to exceed the setting of the valve spring, the fluid unseats
the ball or poppet, allowing a controlled amount of fluid to bypass to reservoir,
maintaining system pressure at the valve setting. The spring re-seats the ball or poppet
when enough fluid is released to drop system pressure below the setting of the valve spring.
Direct-Acting- adjustable

Because the usefulness of a fixed relief valve is limited to the

single setting of its spring, most relief valves are adjustable.
This is commonly achieved with an adjusting screw acting on
the spring. By turning the screw in or out, the operator
compresses or decompresses the spring respectively. The valve
can be set to open at any pressure within a desired range. 
 The force exerted by the
compression spring
exceeds the force
exerted by system
pressure acting on the
ball or poppet.

When system pressure

(P) begins to exceed the
setting of the valve
spring, the fluid
unseats the ball or
poppet, allowing a
controlled amount of
fluid to bypass to
reservoir
Graphical symbol of a relief valve
Working principle (graphical)
Direct acting working principle
• Direct-operated relief valves use system pressure to
generate force to compress a spring.
• This opens a ball or poppet valve, allowing excess fluid to
return to the reservoir.
When a valve
crack open
there is
normally a load
hissing sound
Pressure override
This is a nonlinear response and
Hence its one of the disadvantages
Of directing pressure relief valve

Pressure override: The full-flow pressure minus the cracking pressure.

The pressure override is a measure of the increase in pressure over the
cracking pressure when additional flow passes through the valve after it
cracks.
Characteristics of direct acting P
Relief V
• It uses a stiff spring
• It is normally closed
• It uses poppet valve
• Pressure override is non-linear
• It has internal drain port
• Senses pressure at the inlet
• Comes in adjustable & non adjustable types (not common)

Internal Drain port

Pilot operated relief valve

P
Pilot operated valve
Pilot operated relief valve
• The pilot section of the compound relief valve contains a small,
direct-operated relief valve.
• The pilot section indirectly establishes maximum system
pressure by controlling the pressure in the spring side of the
main valve.
• The main valve poppet disc has a orifice (small opening) that
allows pressurised fluid to pass through to the spring side.
• The spring of the main valve is light (unlike for direct acting),
therefore both the spring and pressure (supplied by the orifice)
keeps the valve shut.
• Pilot operated pressure relief valves are designed to
accommodate higher pressures than direct acting relief valves
at the same flow rate capacity.
Pressure increase…….
As pressurised fluid from the pressure port increases, the fluid will
force the pilot poppet off its seat and the excesses fluid will flow
back to the tank. This in the magic behind pilot operated valve.
Now, since the pressurised fluid + spring pressure/force responsible
to keeping the main valve on seat is changing/reducing on the
spring side, pressure difference is created. Thus there is an
imbalance, or pressure from the pressure port is more than the
pressure on the spring side. When this happens, the main valve
quickly open allowing access pressure to pass to the tank.
Direct acting vs Pilot operated….
Cracking pressure: The point at which the internal
pressure of a hydraulic system triggers or actuates a
valve. Also called the blow-off pressure.

Full-flow pressure: The point at which a relief valve is

diverting flow at its maximum rate.
Direct acting vs Pilot operated

Comparison of action of relief valves at cracking and full flow pressure

Characteristics of a Pilot operated PRV
• It has a pilot valve
• Pressure adjustment is done at the pilot valve
• Suitable for high pressure
• Main valve has an orifice
• Pressure override is fairly linear
• Sense pressure at the inlet port
• It has internal drain port
• It also a poppet type valve
• It is normally closed
Pressure relief valves
Math at cracking and full flow
• 
Example 1- power loss
• 
Example 2- power loss
A pressure-relief valve has a pressure setting of 140 bar. Compute the kW loss
across this valve if it returns all the flow back to the tank from a 0.0016 m3/ s
pump.

Ans

kW power = pQ (Pressure* Flow rate)

= (140x105N/m2 )(0.0016m3/s)x(10-3 )
=22.4 kW
Example 3
A pressure-relief valve contains a poppet with an area of 4.2 cm2
on which the system pressure acts. During assembly, a spring
with a spring constant of 3200 N/cm is installed in the valve to
hold the poppet against its seat. The adjustment mechanism is
then set so that the spring is initially compressed to 0.5 cm
from its free-length condition. In order to pass full pump flow
through the valve at the pressure-relief valve pressure setting,
the poppet must move 0.30 cm from its fully closed position.
• (a) Determine the cracking pressure.
• (b) Determine the full pump flow pressure (pressure-relief
valve pressure setting).
• (c) What should be the initial compression of the spring in
pressure-relief valve if the full pump flow is to be 40% greater
than the cracking pressure?
Solution
(a) Cracking pressure:
Force required to fully close is the product of initial displacement and spring
constant
Fspring = KSinitial = 3200 N/cm x 0.50 cm = ­1600 N

Now we can calculate the cracking pressure knowing the cracking force
Fspring = Cracking Force = Pcracking x Apoppet = 1600N
=> Pcracking x (4.20x10-4m2) = 1600N
> Pcracking = 1600N / (4.20x10-4m2)
=3.81MPa
Solution….
(b) Full pump flow pressure (pressure-relief valve pressure setting):
Force required to fully open is the product of final displacement and spring
constant

Ffullflow = Ksfullyflow = 3200 N/cm x (0.50 +0.3)cm = ­2560 N

Now this force must be equal to product of full pump pressure and area of poppet.

Ffullyopen = Pfull pump flow x Apoppet = 2560 N

=> Pfull pump flow x (4.20x10-4m2) = 2560 N
> Pfull pump flow = 2560 N / (4.20x10-4m2)
= 6.10 M Pa (N/m2)
Solution…..
• Fvalvecosed = KSinitial = 3200 N/cm xL = ­3200L N
Now we can calculate the cracking pressure knowing the cracking force

Fspring = Cracking Force = Pcracking x Apoppet = 3200L

=> Pcracking x (4.20x10-4m2) = 3200L

> Pcracking = 3200L / (4.20x10-4m2)

= 762x104L

Ffullyflow = Ksfullyflow = K(L+0.3) = 3200 (L +0.3)cm = ­3200L + 960

Now this force must be equal to product of full pump pressure and area of poppet.

Ffullflow = Pfullflow x Apoppet = 3200L + 960

=> Pfullflow x (4.20x10-4m2) = 3200L + 960

> Pfullflow = (3200L + 960)/ (4.20x10-4m2)

= (762L+229)x104
We can now calculate the ratio of pump full flow pressure to cracking pressure as

• Ratio = Pfullflow /Pcracking = (762L+229)x104/762Lx104 = 140%=1.40

• Solving for L = 0.75cm.

Example 4
A pressure-relief valve has a pressure setting of 200 bar. Determine the power loss across the valve if
all the pump flow of 120 L/min (litres/minutes) flows back to the reservoir through this valve.

Solution:

Pump flow Q = 120 L/min =120L/(60s) = 2 L/s = 2/1000 m 3 /s = 0.002 m3 /s

• Pressure setting of the valve = 200 bar = 200 × 105 N/m2
• Therefore, the power loss across the pressure-relief valve is
• = Power = PQ in Kilowatt = (200 × 10 5 N/m2 x 0.002 m3 /s )/ 1000= 40KW
Example 5
A pressure-relief valve contains a poppet with a 3.87 cm2 area
on which the system pressure acts. The poppet must move
0.381 cm from its fully closed position in order to pass pump
flow at the pressure-relief valve setting (full pump flow
pressure). The pressure required to overcome the external load
is 68.95 bar. Assume that the pressure-relief valve setting is
50% higher than the pressure required to overcome the external
load. If the valve-cracking pressure is 10% higher than the
pressure required to overcome the external load, find the
following:
• (a) The required spring constant of the compression in the
valve.
• (b) The required initial compression of the spring from its free
length condition as set by the spring adjustment mechanism
of the pressure-relief valve.
Solution
a) At full pump flow pressure, spring force equals hydraulic force on the poppet: Total spring compression ( S) = Initial compression (L)
+ Full poppet stroke

Ffullopen = K(L + 0.00381) =­ 1.5* 68.95*105*3.87/10000 =4002.5 N

= KL + 0.00381K =­ 4002.5 N (1)

Also at cracking pressure, spring force equals hydraulic force on the poppet. Thus, we have
Spring force= Cracking force

KL = PA = 1.1*68.95*105*3.87/10000 =2935.8 N (2)

Substituting values of kin kL in (1), we get

2935.8 N + 0.00381K =­ 4002.5 N => K = 279986.22N/m
Therefore from (2)
KL = 2935.8 N => L = 2935.8/279986.22 = 1.04cm or 0.0104m
 Unloading Valves
Similar in construction to pressure relief valves

Read pressure in an external line, not their own line

Can isolate flow from two pumps based on psi

EX:
Supplies a cylinder from both pumps until a certain psi (say its set for 500)

At 500 psi, the unloading value opens for pump 1 and unloads the pump back to
the tank while pump 2 continues to supply the cylinder. Pump 1 is isolated from the
system.
 Pressure Reducing Valves
Pressure reducing valves maintain a
reduced pressure level in a branch
circuit.

The reducing valve is normally open

while the relief valve is normally closed.

The reducing valve has an external

drain, while the relief valve does not.

Reducing valve can close partially to

create a pressure drop across a valve.
 Sequence Valves
A valve that is a pressure control valve that is
used to force two actuators to be operated in
sequence.

Sends flow to a branch circuit, not back to the

tank.

Can operate remotely

EX: Clamp cylinder extends to hold a work-piece,

Then a second cylinder extends to bend the work-piece.
 Counterbalance Valves
A valve that is a pressure control valve that is
used to prevent a load from accelerating
uncontrollably. Prevents the load from driving the
cylinder.

Apply only to cylinders

Can happen in vertically mounted cylinders where

the load is weight.

Can operate remotely.

Can drain internally, does not have an external

drain.
 Brake Valves
A valve that is a pressure control valve that
is used to prevent a load from accelerating
uncontrollably, just like a counterbalance
valve, except that brake valves only apply
to hydraulic motors.

Prevents the motor from being driven by the

weight, by closing the inlet just enough to
allow enough back pressure on the outlet to
keep the motor in control
 Pressure Compensated Pumps
Limit the maximum pressure by reducing
their displacement.

When pressure reaches a preset level

(firing pressure), the displacement is
reduced to prevent further rise in pressure

Flow will decrease rapidly to zero

EX: Hydraulic Press:

Presses something together until it reaches
its firing pressure
 Pressure Compensated Pumps
EX: A hydraulic press circuit operates at 3500 psi and 10 gpm. When the cylinder is fully
extended and under pressure, the leakage in the system totals 0.4 gpm. Compare the power
consumption when the cylinder is fully extended with and without a pressure compensated pump.

Without: 9.6 gpm is forced over the relief valve and 0.4 gpm is lost due to leakage, both at 3500 psi. Total
energy waste is

With: When the cylinder bottoms out, the pumps displacement will be reduced to 0.4 gpm. The total wasted
energy is
 Pressure Control Valve Mounting
Inline mounting style – fittings that are screwed into the valve

Sub-plate mounting style - have unthreaded connections on the bottom of the valve
 Pressure Control Valve Specifications
What you will see:

Maximum Pressure
Maximum Flow
Filtration level
Fluid Type and viscosity range
Physical size, mounting and porting