Basic Hydraulics

BASIC HYDRAULICS – Course Outline

WHAT FLUID POWER IS AND HOW IT IS USED IN AN EVERYDAY INDUSTRIAL ENVIRONMENT

This course begins with an overview of Hydraulic and Pneumatic principals: What fluid power is and how it is used to perform useful work. We discuss the differences and similarities of Hydraulics and Pneumatics, distinguishing which to use – (when and why, including the use of various physical and natural laws and formulas that govern the use of fluids) – to provide fluid flow to move loads and fluid pressure to support loads, progressing through identifying hydraulic components by their schematic symbols and identifying the components in circuits, what they do and why they are in the circuit, how leakage effects performance and a discussion of common failures. The program is devoted to safety and requirements of creating a “skilled worker”.

This course covers an overview of hydraulic principles and progresses through hydraulic system components including pumps, valves, cylinders, motors, rotary actuators, accumulators and filters with emphasis placed on the component structure and the identification of the components by the proper symbol as standardized by ANSI and ISO.

Methods of instruction include lecture, discussion, audio-visual material including power point presentation and lab exercises with simulation and the use of real-world hydraulic components and problem-solving.

Course Outline

Hydraulic Principles
Positive-Displacement Pumps
Variable Volume and pressure compensated pumps
What Pressure Compensation is and how and why it is used
Flow Control Valves
Directional Control Valves
Pressure Control Valves
Check Valves
Hydraulic Cylinders
Hydraulic Motors
Hydraulic Rotary Actuators
Pilot Operated Pressure Control Valves
Accumulators
Fluid Conductors
Reservoirs, Heat Exchangers and Filters

Purpose of the Training

Being able to operate, maintain and troubleshoot your own hydraulic equipment and systems, starts simply by understanding how all the various components work, what they are doing in the circuit and why they are there. Learning the basic building blocks of fluid power makes the student proficient in working with industrial hydraulics. This course is perfect for beginners, multi-craft technicians needing to understand basic hydraulics and skilled fluid power technicians needing a solid refresher. Time is money and this course is designed to have an immediate impact by saving maintenance dollars on costly repairs, service calls, and needless downtime. Students attending this course are expected to be able to go back to their workplace and immediately apply their new found knowledge to their fluid power systems ……. safely and effectively.

Training Outcomes

Identify hydraulic components and their schematic symbols
Understand the characteristics and applications of primary and auxiliary components.
Selection of the proper components (pumps, valves, motors & actuators) to obtain the desired result.
Design simple hydraulic circuits using schematics.
Diagnose and avoid common systems and component problems.
Understand the differences and commonality of mobile and industrial hydraulics.
Determine applications for installing and charging accumulators.
Determine the proper methods of installing and routing hoses and pipes.
Determine proper filtration and methods of controlling contamination and heat in hydraulic systems.
Working with hydraulic fluids and components in a safe and environmentally friendly manner.
Testing and inspecting hydraulic systems Safely!
Diagnosing system versus components issues.
Evaluate the cause and effect of changing or re-sizing system components.
Identifying methods to prevent future breakdowns and downtime.

COURSE AGENDA

DAY 1 – Hydraulic Systems & Components: What they are and how they work.

We begin with an overview of Hydraulic Principals and progress through hydraulic system components including pump, valves, motors, rotary actuators, accumulators and filters with an emphasis on component structure and identification of the components by the proper symbol as standardized by ISO (International Symbols Organization).

Methods of instruction include discussion, audio-visual material such as power-point and animation of components and valve cut-a-ways.

DISCUSSION TOPICS

* Hydraulic Principles – including Pascal’s, Boyle’s and Charles’ Laws
* Differences between Hydraulics & Pneumatics

• Compressibility of Fluid
• What is Fluid Power?
• Why is Fluid Power used?
• Where is Fluid Power used?
• How Fluid Power is used
• What Fluid Power Systems consist of
• Hydraulic Terminology
• Basic Formulas
• Basic Pneumatic System
• Control valves
• Intermediate Devices
• Power devices
• Basic Hydraulic System
• Side by Side Comparison

* Hydraulic Symbols
* Positive Displacement Pumps (Gear, Vane, Piston)
* Variable Displacement Pumps (Vane and Piston)
* Pressure Compensated & Load Sense
* Check Valves
* Needle Valves
* Flow Control Valves
* Directional Control Valves: 2 – 3 and 4 way – 2 and 3 position
* Pressure Control Valves
+ Relief – Sequence – Counter Balance – Unloading – Reducing – Brake
* Pilot Operated Pressure Control Valves
* Hydraulic Cylinders
* Hydraulic Motors
* Hydraulic Rotary Actuators
* Accumulators (Piston, Bladder & Weighted)
* Power Units
* Fluid Conductors and Fittings
* Reservoirs

DAY 2 – Circuits – and how to identify and fix common problems.

On day 1 students gain a basic “working knowledge” of industrial hydraulic components and their function within an operational system.

Day 2 builds on that knowledge and is designed to help the student become aware of the decision-making process that is part of a logical troubleshooting approach, including doing it safely.

The instructor focuses the class on the selection of the proper components, problem-solving and troubleshooting as a part of a systematic approach to locating malfunctions, their causes and many safety aspects associated with the circuit.

DISCUSSION TOPICS

* Application of Hydraulics
* Heat Exchangers
* Fluids
* Seals
* Contamination Control
* Filters
* Selection of Proper Components based on “Specification Requirements”.
* Troubleshooting:
Basic Troubleshooting Requirements:
+ Noisy and Cavitating Pumps
+ No System Pressure
+ Low or Erratic System Pressure
+ No Actuator Movement
+ System Running Hot
+ Slow or Erratic Actuator Movement
+ Common System Problems
+ Solenoid Failure and Causes
+ Internal and External Leakage Control
+ Safety
+ Web Content for Added Learning

WHO SHOULD TAKE THIS COURSE?

This course is designed for people involved with fluid power at industrial facilities, utilities, or commercial and private building facilities. These attendees come from a wide variety of industries, skill levels, (novice to those needing a refresher) company sizes and job titles. Companies that benefit from these seminars include, but are not limited to:

* Manufacturing Plants
* Utilities
* Waste Water Facilities
* Mining
* Government Facilities
* Oil Refineries
* Drilling Platforms
* Military
* Ship Building and Repair
* Commercial Buildings
* Construction Sites
* Airports
* Any Facility that requires hydraulic implementation and/or repair.

Including:

* Maintenance Mechanics & Technicians
* Fluid Power Technicians
* Machine Operators
* Plant Managers
* Plant Engineers
* Facilities Managers
* Design Engineers
* Pipefitters
* Multi-Craft and those requiring Cross Training of Personnel
* Purchasing Agents
* Any person needing a thorough understanding of fluid schematics.

Upon completion of this course the student will more readily understand THEIR OWN systems and how to identify, prevent and fix common problems; and most importantly, will be able to immediately put this training to use in your facility safely.