The Next Generation ‘Green’ for Maritime Water Hydraulics Customer Focused – Quality Driven – Global Reach
Why Water Hydraulics? Water hydraulics can accomplish the same work as traditional systems, 1 without worrying about the environmental impacts associated with oil based systems. Water hydraulics is a very efficient way to transmit fluid power; water is 2 incompressible with no energy loss attributable to fluid compression. Water hydraulics is naturally fire resistant; please note that advertised ‘fire 3 3 resistant fluid’ can ignite when atomized under pressure. The key is that resistant fluid’ can ignite when atomized under pressure. The key is that water is truly ‘Non Flammable’. Water hydraulics can be used even in below freezing applications; 4 environmentally safe additives can significantly lower the freezing point. Water hydraulics is proven technology and is being used extensively 5 throughout many industries today such as steel, aluminum, mining, medical, food processing…and the list continues to grow. E 3 = E conomical x E co-Friendly x E fficient Customer Focused – Quality Driven – Global Reach
BOC Water Hydraulics, Inc. BOC Water Hydraulics Inc. Presentation to The 12024 Salem-Warren Rd. P.O. Box 1028 Society of Naval Architects Salem, Ohio 44460, USA Phone: +1 330.332.4444 & Marine Engineers Fax: +1 330.332.1650 www.bocwaterhydraulics.com www.facebook.com/bocwaterhydraulics Customer Focused – Quality Driven – Global Reach
Contents • Current Water Hydraulic Applications • Water versus Oil Hydraulics • Cartridge Valves • Fluid Considerations • Marine Based Applications • USACE Dredge MURDEN • Other Marine Applications Customer Focused – Quality Driven – Global Reach
Applications today are Headed Towards Water Water Is Used in Many Applications Today • Water Hydraulics are used today in: – Steel industry (Descaling & DC) – Aluminum (Directional Control) Fire – – Refining (Coke Drum Cutting) Refining (Coke Drum Cutting) – Mining (Roof Support – Process) – Food Processing (Avoid contamination) – And many more . . . • Where are Water Hydraulics applications heading: – Dredging (2012) – Navigation (2015) – Other Shipboard Systems Customer Focused – Quality Driven – Global Reach
Range of Water Systems From low to high pressure; low to high flow Oil & Gas The higher the pressure, the (Decoking) Steel 1000 smaller the components (Descaling) ‘typically’ Flow Flow (GPM) 100 General Industry Steel (Water Cutting) (DCV) Dredging/ Pipe Mills Marine 10 (Hydrotesting) Food Industry (Handling) 5 1000 3000 5000 10000 > 10000 Pressure (PSI) Customer Focused – Quality Driven – Global Reach
Technical Considerations • Design Approach • Practical Realities • Physics • Economic Impact Zero Leakage – Environmentally Friendly – Higher Efficiency – Lower Total Cost of Ownership Customer Focused – Quality Driven – Global Reach
Technical Considerations Oil Hydraulics Water Hydraulics • Design Approach – Zero Leakage. • Design Approach – Typically lapped Internal leakage damages base spool type designs; Internal materials; water is a cutting agent at Leakage is part of design; rely on high pressure and velocity. internal leakage for lubrication Avoidance of internal leakage is key to success Zero Leakage – Environmentally Friendly – Higher Efficiency – Lower Total Cost of Ownership Customer Focused – Quality Driven – Global Reach
Technical Considerations Oil Hydraulics Water Hydraulics • Practical Realities – Given zero • Practical Realities – Plunger floats; leak requirement, most valves use minimal metal to metal contact, no ‘soft’ packed seals; lack of lubricity requirement for high strength/anti- and difficult application environment corrosive materials often requires high strength, more exotic materials such as stainless Zero Leakage – Environmentally Friendly – Higher Efficiency – Lower Total Cost of Ownership Customer Focused – Quality Driven – Global Reach
CLOSED POSITION CLOSED POSITION OPEN POSITION OPEN POSITION SEAL VENT OUT OUT OUT OUT PILOT PILOT DRAIN PRESSURE IN IN IN IN Area 2 > Area 1 • System pressure is vented out of top of • poppet. System pressure is applied to top of poppet to close valve. • Pressure acting on bottom of poppet, • Pressure acting on larger area, (A2), A1, opens the valve. closes the valve. Customer Focused – Quality Driven – Global Reach
CARTRIDGE STYLE CARTRIDGE STYLE DIRECTIONAL DIRECTIONAL CONTROL VALVES CONTROL VALVES • IDEAL FOR WATER SYSTEMS PILOT SECTION: • ZERO INTERNAL LEAKAGE • CONTROLS OPENING AND CLOSING • FLEXIBLE ACTIONS OF CARTRIDGES IN CORRECT SEQUENCE. • MANY VARIATIONS AVAILABLE FROM SOLENOID OPERATED TO LEVER OPERATED. 4 COMMON IDENTICAL CARTRIDGES 4 WAY VALVE 4 WAY VALVE Customer Focused – Quality Driven – Global Reach
CARTRIDGE FEATURES CARTRIDGE FEATURES Slot for fast and easy Threaded hole to support special functions cartridge removal during (spring support, hand wheel installation, maintenance. etc.) Commonality of parts reduces on Dynamic seals do not cross hand spares inventory. ports during valve shift resulting in long valve life and less maintenance. Hex socket for fast, easy removal and torqueing. DIN 80 and up use multiple torque screws. torque screws. Single piece hardened stainless steel sleeve Removable, reversible seat with range of with graduated slots to minimize hydraulic material options (hard and soft) for drop shock. Long component life and less downtime tight sealing – double seal life reducing and system maintenance. maintenance costs. Customer Focused – Quality Driven – Global Reach
Example: F14 Action Example: F14 Action – 3 Position, 4 Way Valve 3 Position, 4 Way Valve SIMPLIFIED SCHEMATIC DETAILED SCHEMATIC Customer Focused – Quality Driven – Global Reach
Technical Considerations Oil Hydraulics Water Hydraulics • Physics – Water does not compress, • Physics – Oil allows for higher makes it more efficient to pump; zero pressure drops and higher velocities, leakage makes it more energy creating smaller components, but at efficient; lower velocities translate to a price of energy loss larger valves. Zero Leakage – Environmentally Friendly – Higher Efficiency – Lower Total Cost of Ownership Customer Focused – Quality Driven – Global Reach
Technical Considerations Oil Hydraulics Water Hydraulics • Economic Impact – Manufactured in • Economic Impact – Manufactured low quantity, price points higher, in volume, price points relatively low much smaller market ($100 M) given large market size (several $Billion per year) Zero Leakage – Environmentally Friendly – Higher Efficiency – Lower Total Cost of Ownership Customer Focused – Quality Driven – Global Reach
Initial Cost Water Hydraulics vs Oil Hydraulics Customer Focused – Quality Driven – Global Reach
Fluid Cost Water Hydraulics vs Oil Hydraulics Tank Description EAL Cost WH Cost Volume Reservoir 350 Gal $13,300 $350 Storage Tank 2000 Gal $76,000 $0 Fluid Makeup Fluid Makeup $38/Gal $38/Gal $1/gal $1/gal Fluid 350 Gal $13,300 $350 Contamination Notes: •Water Hydraulics is filled directly from potable water system. •No clean up cost or fines associated with Water Hydraulics. •No storage, handling, or disposal costs for Water Hydraulics. Customer Focused – Quality Driven – Global Reach
Fluids Considerations • Basic Design – Media is ‘tap water.’ De-ionized or distilled water is not a requirement. Most products designed to work on ‘river water.’ At the extreme – some systems could be designed to work with seawater • Other Low Viscous Fluids – Several low viscous fluids are used throughout industry for special process considerations (aluminum mills throughout industry for special process considerations (aluminum mills use kerosene based fluids to prevent from marking the end product); all require a zero leak design approach • Cleanliness – Some reasonable level of cleanliness (100 microns or better) • Additives – In some applications glycols are added to increase lubricity or to prevent fluid contamination Customer Focused – Quality Driven – Global Reach
Fluid Additives Additives Serve Many Purposes • Purpose - Additives aid the use of water as a hydraulic fluid. Water is limited in its ability to lubricate (low viscosity). It also can be a media for growth of biological agents. Unfortunately, it does freeze at a relatively high temp. • • Corrosion Control – Synthetic additives bond to the internals of the system Corrosion Control – Synthetic additives bond to the internals of the system and prohibit or slow corrosion • Algae Control – Algaecides mix with the fluid and prevent growth of biologics which can degrade system performance • Lubricity Assistance – Other additives are design to add lubricity to the fluid making it slippery and enhancing life of components • Freezing Control - Additives such as Propylene glycol (FDA approved food additive) lower the freezing temperature of the water Customer Focused – Quality Driven – Global Reach
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