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Advanced Hydraulic: Theory and Applications

2 Day Training

Dates: 06 – 07 June 2024
Locations: Johannesburg, South Africa
Platform: Available In-Class / Online

Price: Available on Request

This is a Non-accredited Course

Course Introduction

Advanced Hydraulic: Theory and Applications is a level 2 training course for equipment maintenance personnel who have attended Basic Hydraulic Training or have equivalent knowledge/experience in Hydraulics.  This course is also recommended for plant engineering personnel who are tasked with hydraulic system improvement, system modification and system design. This course builds on the basic hydraulic training course with a more in-depth discussion of the various subjects listed. It also provides a comprehensive discussion of hydraulic components and its operation.

 

Delegates are equipped with a sound knowledge in 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.

Course Objectives

By attending this Advanced Hydraulic Theory and Applications training, delegates will be able to understand:

  • Hydraulic theories and applying them in practice

  • Hydraulic components and Valves

  • The selection of the correct hydraulic filter for different systems

  • A brief recap of the operation of pressure, flow and directional control valves and their applications in hydraulic circuits

  • Common causes of hydraulic failure and how to prevent them

  • Hydraulic filters and cleanliness control

  • 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

  • Calculation of a hydraulic motor application

  • How to build different types of hydraulic circuits

  • The different types of hydraulic control systems and the effect on energy usage

  • Step-by-Step Building of a Hydraulic system

Who should attend?

Advanced Hydraulic: Theory and Applications course is suitable to a wide range of professionals but will greatly benefit:

The technician to the engineer whose job requires and in depth understanding of designing evaluation and applying hydraulic systems efficiently and economically. It is recommended that the delegates attending the advanced course should have attended the hydraulics training course or obtained similar experience. 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 Electromechanical Repair Technicians

  • If you are responsible for the ongoing operation of a fluid-power system, or if you manage or train workers.

Training methodology

Training Methodology

Our diverse instructional approaches ensure effective learning:

– Lectures & Presentations: Engage with expert-driven, stimulating content.
– Course Material: Access well-crafted supporting resources.
– Group Work: Collaborate on discussions and case studies for practical insights.
– Workshops & Role-Play: Participate in immersive, scenario-based activities.
– Practical Application: Focus on applying theoretical knowledge in real situations.
– Post-Training Support: Receive extensive support after training for skill implementation.

Training Outline

Day 1

The Laws and Principles of Hydraulics              

  • An Overview of Hydraulic Principles, Maintenance and 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                

  • Fluid

    • 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 Basics for Hydraulic Systems

  • Inspections:

    • Daily and Monthly Checks

    • Hydraulic Systems Inspection and Service

  • Start up and Maintenance of Hydraulic System

  • Maintenance and Watchkeeping: Simple Maintenance Hints

Day 2

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         

  • Pressure­control valves; incl. Pressure­Relief Valve, Simple Pressure­Relief Valve and Compound Pressure­Relief Valve

  • Directional Control Valves; including Complex Valves, Poppet Valve, Sliding­Spool Valve, Two­Way and, Four­Way 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 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

Step-by-Step Building of a Hydraulic system         

  • Step 1: Understand how a hydraulic system works

  • Step 2: Determine what type of power source your hydraulic system will require

  • Step 3: Look at some simple, everyday hydraulic systems to help you become familiar with their function.

  • Step 4: Plan your hydraulic system project with the design parameters you will require.

  • Step 5: Determine the amount of work your system will do to allow you to size the components

  • Step 6: Choose the appropriate container for your hydraulic fluid reservoir

  • Step 7: Pick a suitable material to plumb up your hydraulic circuit

  • Step 8: Find a suitable valve system for your task

  • Step 9: Select the type of and capacity of your hydraulic pump

  • Step 10: Pair up a suitable motor to your pump

  • Step 11: Hook up your power application component

  • Step 12: Build a support frame that will position each component in a position where it will perform it’s task

  • Step 13: Fill the system with the hydraulic fluid you choose, bleed the air out of it, then pressurize it to check for leaks

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

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