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.
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
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.
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.
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