Advanced Hydraulics Training Course - Best practice in Hydraulic Theory & Applications
This course is also recommended for plant engineering personnel who are tasked with hydraulic system improvement, system modification and system design.
Description
Introduction
The Hydraulic Theory and Applications training course covers understanding of hydraulic systems, using schematic diagrams,installation procedures, maintenance, cleanliness and safety. It discusses planned mechanical maintenance, specific repair/replacement recommendations, system diagnosis, and troubleshooting. Ultimately, it will provide delegates with knowledge of best practices in fault finding techniques and procedures to reduce costly downtime and a greater working expertise and understanding of fluid power systems.
Included are hydraulic principles of mechanical maintenance, types of hydraulic fluids and their characteristics, components of the hydraulic system and their functions for maintenance procedures, including filters and strainers, reservoirs and accumulators, pumps, piping, tubing and hoses, control valves, relief valves, actuating devices, and a variety of cylinders.
Delegates will also understand the design of hydraulic systems, in order for maintenance staff to extend their technical and methodical knowledge. This enables specific issues relating to maintenance to be dealt with in more detail.
Who is this Training Course for?
The technician to the engineer whose job requires and in depth understanding of designing evaluation and applying hydraulic systems efficiently and economically.
People who will benefit from attending this course include:
- Plant Managers
- Maintenance Managers & Personnel
- Filtration, Maintenance & Design Engineers
- Millwrights, Pipe Fitters, Plumbers, Mechanics, Machinery Maintenance Mechanics and Electro-mechanical Repair Technicians
- If you are responsible for the ongoing operation of a fluid- power system, or if you manage or train workers.
Also recommended for plant engineering personnel who are tasked with hydraulic system improvement, system modification and system design and a comprehensive discussion of hydraulic components and its operation.
The Course Content
Day 1
Hydraulic Theory and Principles
- hydraulic theory and physical principles
- Hydrostatics
- Hydrodynamics
- Hydraulic Fundamentals
- Liquid Characteristics
- Transmission of Hydraulic Force
- Pressure
- Head pressure
- Flow
- Friction
- Volume
- Capacity
- Velocity
- Flow Rate
- Heaters and Coolers
- Speed
- Mechanical Advantage
- Advantages and Disadvantages of Hydraulic Systems
- Design of a hydraulic system
- Comparison of the different energy transfer systems
Hydraulic Circuit Diagrams
- Definition and purpose of Hydraulic circuit diagram symbols
- Important Hydraulic circuit diagram symbols
- Hydraulic Pumps and Motors
- Directional Control Valves
- Methods of Actuation
- Pressure Valves
- Flow Control Valves
- Non-Return Valles
- Cylinders
- Transfer of Energy Symbols
- Measuring Devices
- Combination Devices
- Circuit Diagram Tables
- Function Diagrams
- Interpreting Diagrams
- SI units typically used in hydraulics
Hydraulic Theory and Physical Principles
- Principles of hydraulic systems
- Power transmission
- Pascal’s Law
- The hydraulic lever principle
- Applying these theories to a hydraulic cylinder
- Applications for Hydraulics
Hydraulic Fluid
- Introduction to Hydraulic Fluids
- Types of hydraulic Flow
- Calculation of Hydraulic pump and motor displacement
- Flow Rate
Day 2
Fluid Power Connectors and Filtration
- Fluid Power connectors and hose assemblies
- Different threads found in hydraulics
- Hydraulic filtration and cleanliness control
- The importance of good hydraulic filtration techniques
Control, Check, Pressure and Flow Valves
- Directional control valves
- Check valves
- The different types of hydraulic control systems and the effect on energy usage
Practice and Control of Hydraulic Systems
- Pressure control valves
- Pressure Relief Valves
- Pressure Reducing valve
- Sequence Valve
- Over-centre valves
- Flow control valves
- Slip in cartridge valves
- Manifold Block
- Cartridge Valves
- Cover Plates
- Pilot Valves
- Directional control valve
- Proportional Valves
- Directional Control Valves
- Proportional Valves
- Servo Valves
Day 3
Valves and Synchronization of Cylinders
- Operation of hydraulic gear pumps and other fixed displacement pumps
- Synchronization of Cylinders
- Accumulators
- Hydraulic circuit diagrams and application
- Discussion on maintenance and troubleshooting techniques
Safety in the Hydraulics Workshop
- Working with Hydraulic Oils
- Working with Hydraulic Systems
- Lighting and Ventilation
- Hydraulics Maintenance
- Don’t mix components from different manufacturers
- Risk Assessment
- Protective clothing
Day 4
The Laws and Principles of Hydraulics
- Overview of Hydraulic Principles, Maintenance & Application
- Pascal’s Law
- Computing Force, Pressure, and Area
- Bernoulli's Principle
- NASA Aircraft Example
- Advantages of Hydraulic Systems
Causes of Hydraulic Failures
- Common System Faults
- Wear in Hydraulics
- Hydraulic Leaks
- Preventive Maintenance of Hydraulic Systems
- Finding Root Causes
Physical basics of hydraulics and the design of simple hydraulic cylinder system
- Categories of actuators; including Rotary and Linear Actuators
- Hydraulic cylinders classifications; including Single and Double acting cylinders
- Pistons
- Cylinder mountings
Calculation of a hydraulic motor application
- Hydraulic motors
- Limited rotation hydraulic motor
- Hydraulic motor performance
- Mechanical efficiency
- Overall efficiency
- Electro-hydraulic stepping motors
- Pumps
- Hydraulic pumps
- Hydraulic pump types; including Gear, Rotary vane, Screw and Radial piston pumps
- Pumps for open and closed systems
- Multi pump assembly
- Hydraulic pumps, calculation formulas; including Flow, Power Mechanical and Hydraulic efficiency
Theory of Fluid, Pressure, Force & Air
- Characteristics of Fluids
- Movement of Fluid Under Pressure
- Mechanical Advantage
- Handling of Fluids
- Fluids used in Hydraulics
- Flow, Force, Pressure and Air
Theory of hydraulic filters and cleanliness control
- Filter; including Micron, Beta ratio and Filter location
- Filters and Contaminants
- Cleaning Maintenance practice
- Cleaning of parts; including Cleaning of seals, Oil seal installation, Inspecting castings and machined surfaces, Gaskets, seal rings and 0-rings
- Cleaning and Flushing for Hydraulic Systems
- Inspections:
- Daily and Monthly Checks
- Hydraulic Systems Inspection and Service
- Start up and Maintenance of Hydraulic System
- Maintenance and Watch keeping: Simple Maintenance Hints
Day 5
Thermal control of hydraulic systems
- Define and explain Heat Exchangers
- Heat dissipation heat exchangers:
- Air-cooled and Water Cooled
- Advantages & Disadvantages
Hydraulic components and Valves
- Pressure control valves; incl. Pressure Relief Valve, Simple Pressure Relief Valve and Compound Pressure Relief Valve
- Directional Control Valves; including Complex Valves, Poppet Valve, Sliding Spool Valve, Two-way and, Four Way Valves.
- Control Valve Repair
- Proportional valves; including Proportional Control Valve Circuits and Circuits with proportional throttle valves
- Typical conventional valve circuit with resistive load
- Cartridge valves; including slip-in cartridge valves
- How to Monitor A Hydraulic Machine’s ‘Vital Signs'
Hydraulic Accumulators, Circuits and Control Theory
- Accumulators – selection of and calculation of size;
- Including the following
- Weight-loaded-type, Spring-loaded-type, Gas-loaded-type, Non-separator type, Piston-type separator gas-loaded and Bladder-type separator gas-loaded accumulators
- Accumulator applications
- An auxiliary power source
- Leakage compensator
- Hydraulic shock absorber
Hydraulic control theory
- Pressure compensation and load sensing, closed loop and open loop
- Control valves
- Control components in a hydraulic system
- Centering washers
- Simple pressure relief valve
- Pressure-compensated flow control valves
- The Hydraulic Lever
Course Objectives
This course will provide delegates with an understanding of:
- How hydraulic theories are applied in practice
- The operation of pressure, flow and directional control valves and the applications in hydraulic circuits
- Hydraulic pumps and motors and the control thereof
- Hydraulic cylinder construction and good sealing practices
- Hydraulic circuit applications
- Hydraulic components and Valves
- Common causes of hydraulic failure and how to prevent them
- Hydraulic pumps and motors and the control thereof
- Physical basics of hydraulics and the design of simple hydraulic cylinder system
- Hydraulic cylinder construction and good sealing practices
- How to build different types of hydraulic circuits
- Step-by-Step Building of a Hydraulic system