FSC Blog

Designing for Efficiency: Hydraulic Accumulators for Energy Management

Get ready for a sneak peek into the fascinating world of energy-efficient technology! Recently, Fluid System Components (FSC) teamed up with HYDAC, an industry leader in hydraulic system components, and one of our long-term customers to create a custom accumulator rack. The primary objective of this project was to enhance reliability and decrease energy consumption.

Lowering Energy Consumption: The Versatility of Accumulators in Hydraulic Systems

FSC has a long-standing relationship with HYDAC, and their team of experts was crucial in completing a solution that fit the customer's needs. Accumulators are highly versatile tools for managing energy consumption in hydraulic systems, however, calculating energy savings is not a one-size-fits-all endeavor. Energy savings is dependent on several differing factors, including the duty cycle of the application and the sizing restrictions/needs of the accumulator. By defining the process cycle, it is often possible to downsize the hydraulic system and tap into the energy storage potential of accumulators, which can significantly lower energy consumption.

The accumulator rack is a critical component in the customer's process, storing energy to be used when more flow is needed or in case of a power outage and maintaining a consistent hydraulic fluid pressure. The FSC team worked closely with the customer to define the process cycle and determine the system's energy storage needs, safety considerations and overall reliability.  

Custom Designed Accumulator Rack

This build included hydraulic accumulator safety blocks, which are designed to prevent accidents or system failures by stopping the flow of hydraulic fluid and to isolate the accumulator from the rest of the hydraulic system. This ensures that pressure and stored energy are safely contained, providing peace of mind to operators and engineers. From a safety standpoint, servicing the unit is a huge concern. The safety block also dumps the stored energy when shut down which increases safety during service.

To ensure reliability, two HYDAC large piston accumulators were used to store hydraulic energy in the form of pressurized hydraulic fluid. They can absorb surges in pressure or flow, and then release the stored hydraulic energy when it is needed to supplement the pump flow or pressure. This helps to regulate the hydraulic system's pressure, reduce pulsations, and prevent damage to the system from pressure spikes. Large piston accumulators are particularly effective for high flow and high-pressure hydraulic applications, as they can store substantial amounts of hydraulic energy and release it quickly when required.

CO2 gas bottles are typically used in hydraulic accumulator racks as a source of compressed gas to provide the pre-charge pressure in the hydraulic accumulators. The benefits of using C02 gas include:  

·     The compressed gas in the bottle can be easily regulated to achieve the desired pre-charge pressure.  

·     CO2 gas is non-reactive with hydraulic fluid, ensuring that there is no contamination or degradation of the fluid. 

·     CO2 gas is non-flammable, making it a safe option for use in industrial applications. 

The end result: a happy customer! 

 

Dream it. Build it. Fix it.

This project was a great success, and the customer was pleased with the reliability and energy savings achieved using the accumulator rack. FSC was able to utilize their expertise in hydraulic system components and work closely with the customer to design and build a system that met their specific needs.

We take great pride in delivering unparalleled support across all aspects of fluid hydraulics, with a wide range of products readily available, technical expertise, efficient distribution, precise manufacturing, responsive service and repair, and the utmost level of customer satisfaction.

If you are interested in moving towards energy-efficient technology, connect with us at: (920) 337-0234 or via Email.