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Fluid Power and Hydraulic Systems: Operations and Maintenance

Pumps, Part 1

Course #: 286001
Duration: 10 hours
Course Prerequisites: Hydraulic Components: Actuators, Pumps, and Motors (286061);
What Students Learn: Modern Centrifugal Pumps; Operating Principles of Pumps; Classifications and Types of Pumps; Fundamental Pump Terms: pressure, vapor pressure, head, losses, cavitation, net positive suction head, specific speed, viscosity; Centrifugal Pump Performance Curves; Types of Pumping System Curves.

Special Notes:

  • This updated course replaces course 2530A.
  • The entire course consists of study units 286001, 286002, and 286003.

    • Pumps, Part 2

    Course #: 286002
    Duration: 10 hours
    Course Prerequisites: Hydraulic Components: Actuators, Pumps, and Motors (286061);
    What Students Learn: Construction details of Centrifugal Pumps; Applications of Centrifugal Pumps; Installation and Maintenance of Centrifugal Pumps; Troubleshooting problems associated with Centrifugal Pump Operation.

    Special Notes:

  • This updated course replaces course 2530A.
  • The entire course consists of study units 286001, 286002, and 286003.

    • Pumps, Part 3

    Course #: 286003
    Duration: 10 hours
    Course Prerequisites: Hydraulic Components: Actuators, Pumps, and Motors (286061);
    What Students Learn: Rotary Pumps: classifications, installation and operating principles; Reciprocating Pumps: classifications, installation and operating principles; Power Pumps; Applications of Rotary and Reciprocating Pumps; Troubleshooting Rotary and Reciprocating Pumps.

    Special Notes:

  • This updated course replaces course 2530B.
  • The entire course consists of study units 286001, 286002, and 286003.

    • Introduction to Fluid Power

    Course #: Block Y01
    Duration: 32 hours
    What Students Learn: The objective of this block is to provide the trainee with an introduction to the concepts, applications, and maintenance of fluid power systems. The course covers the common terms and the diagrams and schematics used in the fluid power systems found in a typical manufacturing facility. The physical concepts relating to energy transmission are described. Operation of the primary fluid power components are discussed in detail  pumps, compressors, accumulators, pressure valves, and receivers. An overall systems integration and performance approach is used to assist the trainee in understanding key points. This course can be beneficial to an apprentice, at the entry or skilled worker level, and the mechanical maintenance staff. It will fit well in a mechanical cross training program developed for electrical or multi-craft workers.
    Components: The Components of Fluid Power, Part 3 (Y0107); A Summary of Fluid Power (Y0108); Introduction to Fluid Power (Y0101); The Physics of Fluid Power (Y0102); Transmission and Storage of Energy by Fluid Power, Part 1 (Y0103); Transmission and Storage of Energy by Fluid Power, Part 2 (Y0104); The Components of Fluid Power, Part 1 (Y0105); The Components of Fluid Power, Part 2 (Y0106); Progress Examination (Y0121); Progress Examination (Y0122); Progress Examination (Y0123); Progress Examination (Y0124); Progress Examination (Y0125); Progress Examination (Y0126); Progress Examination (Y0127); Progress Examination (Y0128);

    Introduction to Fluid Power

    Course #: Y0101
    Duration: 4 hours
    What Students Learn:

  • Introduce the basic principles of fluid power and describe their practical application in the generation, transmission, control, and distribution of energy.
  • Establish a basic vocabulary of the terms used within fluid power.
  • Build an awareness of the size, shape, and function of generic fluid power systems and their components.
  • Recognize the graphic symbols used to represent primary system components.
  • Use three conventional systems that graphically portray fluid power systems.
  • Identify five of the physical properties of fluid power, and discuss their impact.
  • Describe the process of energy generation, transmission, storage, control, and delivery by means of a fluid power system.
  • Describe the application of system components and discuss their behavior in relation to overall system performance.

    • The Physics of Fluid Power

    Course #: Y0102
    Duration: 4 hours
    What Students Learn:

  • Describe the physical concepts of force, torque, energy, work, and power as they relate to fluid power system output, and describe their relationships.
  • Apply physical principles, such as the Law of Conservation of Energy and Pascal's Law, to fluid power systems.
  • Identify the components of fluid systems that generate force and torque.
  • Describe the roles and relationships of pressure, resistance, and inefficiency, and discuss their effect on fluid system performance.
  • Explain the features and benefits of energy transmission and control by means of fluid power.

    • Transmission and Storage of Energy by Fluid Power, Part 1

    Course #: Y0103
    Duration: 4 hours
    What Students Learn:

  • Describe how a maintenance technician must analyze and repair an overall fluid power system by diagnosis of the individual component parts.
  • Define the characteristics of fluids.
  • Describe the differences between liquid and gas system behavior as it relates to power level, speed, cost, efficiency, and maintenance.
  • Discuss the selection criteria for commonly used fluids, and describe current equipment trends that have been effected by fluid considerations.
  • Identify fluid system connectors and conductors, and discuss their selection and maintenance.
  • Describe the two major categories of output actuators, and the service and maintenance requirements for the devices most commonly applied.
  • Discuss the performance characteristics and pressure ratings for each category of device and the recommended service and maintenance.

    • Transmission and Storage of Energy by Fluid Power, Part 2

    Course #: Y0104
    Duration: 4 hours
    What Students Learn:

  • Discuss the devices used for energy transmission and storage - accumulators, receivers, pressure vessels, pumps, and compressors.
  • Describe how fluid power amplifiers - boosters and intensifiers - operate.
  • Describe how control and interface systems are designed and how they manage the transmission of energy by means of fluid power.
  • Identify directional controls, pressure controls, flow controls, special flow control systems and proportional controls, and how these systems work.
  • Understand the principles of viscosity, lubricity, friction, inertia, and heat as related to fluid power systems.

    • The Components of Fluid Power, Part 1

    Course #: Y0105
    Duration: 4 hours
    What Students Learn:

  • Discuss the characteristics of fluids (gases and liquids) and their impact on system performance.
  • Describe the critical influence of connectors and conductors, and relate the most common variables to system performance.
  • Explain the differences between linear and rotary actuator systems, and discuss common and differing influences of fluid compatibilities, construction, performance characteristics, ratings, and service recommendations.
  • Understand how pneumatic receivers and pneumatic pressure vessels operate.
  • Understand how hydraulic accumulators and hydraulic receivers operate and are maintained.

    • The Components of Fluid Power, Part 2

    Course #: Y0106
    Duration: 4 hours
    What Students Learn:

  • Discuss typical industrial pumps and compressors and explain basic designs and service considerations, such as fluid compatibility, displacement, compression ratio, heat of compression, and suction pressure.
  • Explain the theory of pressure intensification and discuss the designs of boosters and intensifiers that are applied to achieve the objectives of amplified pressures.
  • Discuss the critical design considerations that identify the devices specific to directional, pressure, and flow control.
  • Describe the relationship of each device category to the objectives of integration and overall system parameters.

    • The Components of Fluid Power, Part 3

    Course #: Y0107
    Duration: 4 hours
    What Students Learn:

  • Discuss the critical design considerations that are relevant to proportional and servo control systems and the specific devices that enable their performance.
  • Describe fluid conditioning and storage devices, and discuss their function and contribution to successful fluid system performance.
  • Explain the theory of operation and use of heat exchangers in hydraulics, and discuss their limited use in pneumatic systems.
  • Discuss the design and application considerations relative to pressure gauges, flow monitoring devices, pulsation dampers, shock absorbers, gauge snubbers, air-bleed vents, and other common performance enhancements.
  • Describe the relationship of each category of devices to the total system, with regard to the objectives of integration and overall system parameters.

    • A Summary of Fluid Power

    Course #: Y0108
    Duration: 4 hours
    What Students Learn:

  • Develop a workable understanding of overall fluid power systems design and performance applications.
  • Discuss fluid power as a means of controlling and powering motion and process.
  • Describe energy transfer by means of fluid power systems.
  • Describe typical problems, identify the most common causes, and prescribe initial steps to analyze and correct these problems.
  • Work comfortably and safely in the industrial environment with a demonstrated awareness of fluid systems, common devices, and the potential hazards of incorrect maintenance practices.
  • Focus on product applications and problem solving within the following devices:
    - Pneumatic lubrication circuits
    - Hydraulic filtration circuits
    - Hydraulic pump control circuits
    - Automated process control circuits
    - Using pneumatically timed sequential control
    - Using pneumatic moving part logic
    - Hydraulic pump assist circuits
    - Special purpose I/O interfaces

    • Fluid Power

    Course #: VB24XX
    Duration: 1.47 hours
    What Students Learn: This program is the ideal way to introduce first year students and entry level trainees to the basic concepts and principles of fluid power. Vivid computer graphics, along with real actuators and valves which have been cut open to reveal internal operations, help drive the very concepts that need to be remembered.
    Components: Principles and Fluids (VB2401); Actuators (VB2402); Controls (VB2403); Pumps and Power Units (VB2404);

    Hydraulic Power Basics

    Course #: 286060
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Introduction to Hydraulic Power; Physical Principles of Hydraulic Power and Energy; Pascal's Law; Bernoulli's Principle; Work and Power; Horsepower and Loss; Hydraulic Power Systems; Basic Components of Hydraulic Systems; Basic Hydraulic System Accessories; Fittings and Couplings; Characteristics of Hydraulic Systems; Comparing Power Systems; Requirements for Hydraulic Systems; Properties of Hydraulic Fluid; Fluid Storage, Handling, and Maintenance; Filters and Strainers; Heat Exchangers; Eliminating Air; Examples of Hydraulic Systems; Proportional Displacement; Hydraulic System Operation; Working Safely with Hydraulic Systems.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Components: Actuators, Pumps, and Motors

    Course #: 286061
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Actuator Design, Detail, and Operation; Linear Actuators; Hydraulic Actuator Components; Rotary Actuators; Pumping Principles; Slippage; Pump Classifications; Gear Pumps; Vane Pumps; Double Pumps; Gear and Vane Pump Lubrication and Capabilities; Piston Pumps; Screw-type Pumps; Supercharging Pumps; Variable-displacement Pump Control Fundamentals; Hydraulic Motors; Comparing Pumps and Motors; Gear Motors; Screw Motors; Vane Motors; Piston Motors; Abutment-type Motors; Losses through Fluid Motors; Deceleration and Braking.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Components: Conductors, Conditioners, and Fluids

    Course #: 286062
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Reservoirs and System Components; Types of Reservoirs; Reservoir Volume; Reservoir Components; Reservoir Interior Care and Auxiliary Tanks; Reservoir in Use; Practical Tips for Reservoir Selection and Maintenance; Conductors, Fittings, and Seals; Maintenance Tips for Conductors, Fittings, and Seals; Choice of Conductor Size and Materials; Types of Heat Exchangers; Automatic Temperature Control; Effective System Cooling Tips; Accumulators; Circuits Using Accumulators; Accumulator Safety; Hydraulic Fluids; Petroleum-based Fluids; Viscosity; Demulsibility; Oxidation Stability; Lubricating Value; Corrosion and Rust Prevention; Fire-resistant Fluids.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Power System Control

    Course #: 286063
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Explain the Function of Control Components in a Typical Hydraulic System; Identify Control Valves by Pressure, Flow, or Directional Type; Explain the Operating Principles and Typical Internal Parts of Pressure, Flow, and Directional Valves; Interpret Schematic Symbols which represent Control Valve Configurations.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Interpreting Hydraulic System Schematics

    Course #: 286064
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Typical Schematic Layout; Recognizing Standard Schematic Symbols; Interpreting Control Configuration from Schematic Symbols; Evaluating System Operating Characteristics from Schematics.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Power System Troubleshooting

    Course #: 286065
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Sizing Components to meet Requirements; Measuring and Evaluating System Operation; Assessing Motor and Pump Capacity and Performance; Special System Control including Servos and Pressure, Temperature, and Limit Switches; Performing Periodic Maintenance and Analyzing Inspection Information; Troubleshooting System Faults; Typical Hydraulic System Faults and Failures.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Power Systems and Troubleshooting

    Course #: VS64XX
    Duration: 0.73 hours
    What Students Learn: This course is ideal for students employed as engineers and others who require an advanced understanding of hydraulic systems operation and maintenance. From examining basic to complex circuitry, students will learn to troubleshoot and repair hydraulic systems.
    Components: Hydraulic Power Systems and Troubleshooting, Volume 1 (VS6401); Hydraulic Power Systems and Troubleshooting, Volume 2 (VS6402);

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