Practical Hydraulic Systems: Operation and Troubleshooting

THE WORKSHOP

Whatever your hydraulic applications, you can increase your knowledge of the fundamentals, improve your maintenance programs and become an excellent troubleshooter of problems in this area by attending this information packed course. Developing an understanding of "how" it works leads to an understanding of how and why it fails. Multimedia views of the equipment are given to give you as realistic a view of hydraulic systems as possible.

The hydraulics workshop is a comprehensive, highly practical and interactive workshop. You will have an opportunity to discuss hydraulic systems construction, design-applications, operations, maintenance and management issues and be provided with the most up-to-date information and best practice in dealing with the subject. Towards the end of the workshop, you will have developed the skills and ability to recognise and solve hydraulic problems in a structured and confident manner.

WHAT IS INCLUDED?

  • Receive a certificate of attendance in support of your continuing professional commitment
  • All workshops include the associated hardcopy technical manual
  • Printed workshop handouts
  • Lunch and refreshments
  • Interact and network with workshop attendees and experienced instructors
  • Practical, industry driven content to assist you in your continuing professional development (CPD)
  • Attendees automatically become IDC subscribers and receive exclusive deals and technical content every month

WHO SHOULD ATTEND?

  • Consulting engineers
  • Design engineers
  • Maintenance personnel
  • Mechanical engineers and technicians
  • Plant engineers
  • Plant operations crews
  • Process operators and technicians
  • Operation, maintenance, inspection and repair managers, supervisors and engineers

CONTENT SUMMARY

INTRODUCTION TO HYDRAULICS

  • Origin of hydraulics and classification

FUNDAMENTALS

  • Force, work, power, energy, mass, weight, torque, density, specific gravity and specific weight

PRESSURE AND FLOW

  • Definition and units of pressure measurement
  • Pascal’s law and applications
  • Pressure - force relationship
  • Fluid flow/discharge
  • Steady and unsteady flows
  • Bernoulli’s principle
  • Laminar and turbulent flows
  • Pressure - flow relationship

HYDRAULIC PUMPS

  • Principle of pump operation
  • Classification (positive and non-positive displacement)
  • Gear pump
  • Vane pump (variable volume and pressure compensated variable volume pumps)
  • Piston pump (axial/inline, bent axis, radial, variable volume, pressure compensated and over centre axial pumps)
  • Gerotor pump
  • Rating of pumps
  • Pressure, flow and efficiencies of pumps

HYDRAULIC MOTORS

  • Principle of motor operation
  • Classification (rotating and piston type)
  • Gear motors
  • Vane motors
  • Piston motors
  • Difference between hydraulic motors and hydraulic pumps
  • Specification of hydraulic motors
  • Efficiency of hydraulic motors
  • Motor slippage

HYDRAULIC CYLINDERS

  • Classification (single and double acting)
  • Construction of cylinders
  • Cylinder mounting
  • Seals
  • Cylinder design checklist
  • Common cylinder problems

CONTROL VALVES

  • Purpose
  • Classification (direction, pressure and flow control valves)
  • Valve symbols

DIRECTION CONTROL VALVES

  • Poppet valve
  • Check valve
  • Spool valve (rotary and sliding valves)
  • Direct and indirect operated valves
  • Valve actuation methods (manual, electrical, pilot, pneumatic, electro-hydraulic and electro- pneumatic)
  • 2,3 and 4 way direction control valves
  • Positive and negative overlapping
  • Centre conditions (open centre, closed centre, tandem centre and float centre valves)

PRESSURE CONTROL VALVES

  • Relief valves (pressure regulating and emergency relief)
  • Meaning of surge pressure
  • Sequence valves
  • Counterbalance valves
  • Pressure reducing valves
  • Unloading valves

FLOW CONTROL VALVES

  • Classification (non-pressure compensated and pressure compensated)
  • Location of flow control valve (meter-in, meter-out and bleed-off circuits)

ELECTRO-HYDRAULIC SYSTEMS

  • Proportional solenoid
  • Proportional valves (direction control, flow control and pressure control valves)
  • Servo valves (direction and pressure servo valves, single stage and multi stage servo valves)
  • Use of transducers in hydraulic systems

HYDRAULIC ACCESSORIES

Reservoirs (pressure and non pressure types)

  • Need for breather and baffle plates
  • Role of hydraulic oil tank in heat dissipation

Accumulators

  • Function and types (dead weight, spring load and hydro-pneumatic)
  • Accumulator sizing
  • Application of accumulators in hydraulic circuitS
  • Heat ExchangersFunction and types (air cooled and water cooled)

Hydraulic Pipes and Hoses

  • Pipe specification and materials
  • Pipe fittings
  • Recommended oil speeds for selecting  pipe sizes
  • Construction of hoses
  • Reinforcement and cover variations
  • Criteria for hose selection
  • Sizing of hoses
  • Maintenance of pipes and hoses

HYDRAULIC FLUIDS

  • Cavitation
  • Aeration
  • Locations of filters and strainers
  • Filter terminology
  • Measurement of contamination levels

APPLICATION OF HYDRAULIC CIRCUITS

  • Symbols of hydraulic components
  • Need for check valve in hydraulic circuits
  • Regenerative circuit
  • Flow equaliser
  • Counterbalance circuit
  • Pre fill and compression relief circuit
  • Decompression circuit
  • Circuits of open centre, closed centre, tandem centre and indirect control
  • Hydraulic circuits of various machines

TROUBLESHOOTING HYDRAULIC SYSTEMS

  • Flow chart analysis of hydraulic circuits
  • Maintenance

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