‘Professional in Pneumatics & Hydraulics – Advanced Level with TUV Rheinland Certified Qualification’ (6 Weeks)
BRIEF COURSE CONTENT
Pneumatics: Safety practices, Industrial prime movers, Compressed air generation and treatment, Pneumatic actuators, Valves and control circuits, Electro-pneumatics, Multiple-actuator pneumatic and electro-pneumatic circuits, Pneumatic applications, Design, and Maintenance and troubleshooting of pneumatic systems.
Hydraulics: Hydraulic safety, Hydraulic fundamentals, Fluids, Filters, Power packs, Pumps, Pressure relief valves, Linear actuators, Rotary actuators, Hydrostatic transmission (HST), Directional control valves, Non-return valves, Flow control valves, Pressure control Valves, Accumulators, Seals, Fluid conductor system, Electro-hydraulics, Proportional valve system, Servo valve system, Basics of hydraulic cartridge valve systems, Load Sensing Systems, Applications of hydraulic systems, Preventive maintenance & troubleshooting, and Design of hydraulic systems.
Programmable Logic Controllers (PLCs)
Employability Skills: Stress Management, Decision Making & Problem Solving, Team Building, Interpersonal Skills, Leadership, Time Management, Communication Skills, and Emotional Intelligence.
The examination, consists of written test (60 minutes), practical test (120 minutes) and viva (30 minutes).
The examination is monitored by an examiner nominated by TÜV Rheinland (India) Private Limited. The examination is evaluated according to the examination criteria defined by the certification body.
A candidate is regarded as passed the examination, when the candidate has achieved a minimum of 67% in each of the written, practical & oral exams.
LIST OF SHORT-TERM COURSES
- Industrial Hydraulics – Basic Level (6 Days)
- Design of Industrial Hydraulic Systems (5 Days)
- Pneumatic controls -Basic Level (4 Days)
- Electro-pneumatics and Automation – Basic Level (4 Days)
- Design of Pneumatic Systems (5 Days)
- Programmable Logic Controller (PLC) with Pneumatic/Hydraulic Applications (4 Days)
- Human Machine Interface (HMI) (3 Days)
- Pneumatic controls –Advanced Level (3 Days)
- Electro-pneumatics – Advanced Level (3 Days)
- Hydraulic Fluids and their Contamination Control (2 Days)
- Hydraulic Filters: Constructional Details, Ratings, and Maintenance (1 Day)
- Maintenance and Safety of Hydraulic and Pneumatic Systems (2 Days)
- Fluidsim-P / Fluidsim-H (2 Days)
- Advanced Pneumatics (4 Days)
- Advanced Electro-pneumatics (4 Days)
COURSE CONTENTS – SHORT-TERM COURSES
INDUSTRIAL HYDRAULICS – BASIC LEVEL (6 Days)
On completion of the course, the participants will be able to understand the basic hydraulic concepts, functions and differentiating characteristics of the many hydraulic components. They will be able to develop hydraulic circuits using simulation software and construct, test and operate hydraulic circuits. They will also be able to interpret hydraulic drawings, identify the major hydraulic system components, and describe their expected function. The topic coverage includes: Basic hydraulic principles (Pressure, flow, force multiplication, etc), fluid characteristics, filtration, power pack, reservoir, pumps, pressure relief valves, hydraulic actuators, hydraulic symbols, directional control valves, check valves – direct and pilot operated, flow control valves – meter-in, meter out, bleed-off, pressure control valves, Accumulator basics, fluid conductors and fittings, and maintenance, troubleshooting, and safety precautions.
DESIGN CONSIDERATIONS FOR INDUSTRIAL HYDRAULIC SYSTEMS (5 Days)
This course covers the topic of how to select and properly size components used in industrial hydraulic systems. The topics discussed include the selection and sizing of the reservoir, pumps, valves, actuators, heat exchangers, filters, and fluid conductors for a hydraulic system. The course is math-intensive, as basic math and physics are used to calculate the required performance specifications for various applications. After undergoing the course, the participants will get the knowledge in the systematic approach to the design of hydraulic systems.
ELECTRO-HYDRAULIC SYSTEMS AND CIRCUITS (4 Days)
On completion of the course, the participants will be able to understand the functions and applications of electro-hydraulic power and control system components. The power components include solenoids, discrete solenoid valves (3/2-way single-solenoid, 4/2-way single-solenoid, 4/2-way double-solenoid etc). The control components include push-button stations, electromagnetic relay, limit switches, reed switches, proximity sensors, time-delay relays, and counters. The participants also get a chance to familiarize with the logic controls, latching circuits and other memory circuits, semi-automation and complete automation, time delay circuits, and counter circuits. They will have hands-on with these circuits.
PNEUMATIC CONTROLS – BASIC LEVEL (4 Days)
The basic course on pneumatic controls is tailored to impart the know-how of pneumatics to the requirements of the modern industries. The course covers, in detail, the safety aspects of pneumatic systems and the compressed air generation and preparation methods, pneumatic actuating mechanisms, various control techniques, and brief maintenance and troubleshooting aspects. The relevant ISO symbols are introduced. The classroom teaching is supplemented by the use of simulation software packages and power point presentations followed by practical sessions. Proper safety procedures and appropriate working practices are followed throughout the course, especially during the practical sessions. This course provides maintenance personnel and production operators with the skills and knowledge necessary to carry out maintenance tasks on pneumatic systems. On completion of the course, the participant will also be able to identify pneumatic components, develop/interpret control circuits, and carry out proper maintenance of pneumatic systems.
ELECTRO-PNEUMATICS AND AUTOMATION – BASIC LEVEL (4 Days)
The basic course on electro-pneumatic controls aims at empowering the participants with the skills to develop, construct, and test the electro-pneumatic circuits using a single actuator. The course also covers the functions and operation of a range of electrical control components and sensing devices. A number of electrical relay circuits are developed for controlling pneumatic systems. The classroom teaching is supplemented by the use of magnetic symbols, simulation software packages, power point presentations followed by practical sessions. Proper safety procedures and appropriate working practices are followed throughout the course, especially during the practical sessions. This course provides maintenance personnel and production operators with the skills and knowledge necessary to carry out maintenance tasks. On completion of the course, the participant will also be able to understand the construction and function of various components in electro-pneumatic control systems. He will also be able to identify and use control schematics, design, construct, and troubleshoot single-actuator electro-pneumatic circuits.
P L C (4 Days)
The course covers the following topics: Basics of Pneumatics / Hydraulics – Power source, actuators, solenoid valves, PBs, and sensors, Hard-wired Control Systems, Programmable Control Systems, Hardware aspects of PLCs: System Components, CPU, Memory organization, Power Supply unit, I/O Section, Analog/Digital I/Os, Modular PLCs, Software aspects of PLCs: Operating System, Hardware configuration, User programs, Program scan-cycle, Programming elements: Bit logic operations, NO contact, NC contact, Coil, Timer, Counter, Multiple actuator programs, and Program techniques.
Note: Practicals with Pneumatic / Hydraulic Applications will be carried out using OMRON PLC.
SUGGESTED COURSE CONTENTS – ON-DEMAND COURSES
PNEUMATIC CONTROLS – ADVANCED LEVEL (4 Days)
The course is a natural progression from the basic level pneumatic course. Therefore, prior knowledge of the basic pneumatics is necessary for the proper understanding of the advanced level course. The course covers the safety aspects of pneumatic systems and the control techniques of multiple actuator circuits using the cascade method and the shift register method. The participant will be tested for their skills in developing, constructing, and testing advanced industrial pneumatic circuits using our hands-on trainer kits. The course is suitable for anyone who is required to design or maintain industrial pneumatic systems.
ELECTRO-PNEUMATICS – ADVANCED LEVEL (4 Days)
The course is a continuation to the basic level electro-pneumatic course. The course comprehensively covers the control techniques of multiple actuator electro-pneumatic circuits using the cascade method and the shift register method. The participant will be tested for their skills in designing, constructing, and testing advanced industrial electro-pneumatic circuits. The course is suitable for design engineers, plant engineers, maintenance staff and instructors involved in the industrial electro-pneumatic systems.
HYDRAULIC FLUIDS AND THEIR CONTAMINATION CONTROL (2 Days)
On completion of the course, the participants will be able to understand the following real facts of hydraulic fluids. That is, their functions & characteristics, contamination & its control, fluid cleanness standards, cleanliness level targets, and hydraulic fluid analysis. They will know the origin and nature of contamination and their effects on hydraulic components. They will use their acquired knowledge to interpret the fluid laboratory reports. They will also be able to carry out various maintenance activities on hydraulic fluids. The participants also get a chance to familiarize with different types of hydraulic fluids and have a hands-on with the viscosity measurement, fluid sampling, patch test, etc.
HYDRAULIC FILTERS: CONSTRUCTIONAL DETAILS, PERFORMANCE RATINGS, AND MAINTENANCE (1 Day)
On completion of the course, the participants will be able to understand various facts of hydraulic filters. This includes filter materials, filter classifications, filter with bypass valve, duplex filter. The topics also include filters according to installation locations. The performance specifications of hydraulic filters such as the mesh number, micron ratings, Beta ratio, filter efficiency, particle capture efficiency, and differential pressure (ΔP), the Multipass test, are also covered. They will use their acquired knowledge to carry out various maintenance activities on hydraulic filters. The participants also get a chance to familiarize with different types of hydraulic filters.
MAINTENANCE AND SAFETY OF HYDRAULIC AND PNEUMATIC SYSTEMS (2 Days)
On completion of the course, the participants will be able to understand the planned maintenance, and specific repair/replacement recommendations. They will also understand the system diagnosis and troubleshooting of hydraulic and pneumatic systems. The course objectives include identifying common hazards associated with the workplace. The course objective also include describing proper procedures for working with various hydraulic and pneumatic components. Further, the course covers the listing the safety rules that must be followed when operating or maintaining a hydraulic and pneumatic system. The course is ideally suited for maintenance personnel, engineers, first line supervisors. The course is also essential for anyone desiring an in-depth understanding and appreciation of hydraulic and pneumatic system component operation and logical troubleshooting techniques.
FLUIDSIM-P / FLUIDSIM-H (2 Days)
The course is designed to provide a general overview of the main functionalities, libraries, and modules of the Fluidsim-P / Fluidsim-H software package. It helps the participants in the use of design features, and simulation and animation features. The course empowers the design, training, sales, production, and maintenance personnel for developing, simulating, and analyzing pneumatic circuits.
ELIGIBILITY FOR SHORT-TERM COURSES
ITI/ Diploma/ Graduate in Engineering / Technology
Admission for the scheduled courses will be given to eligible candidates on first-come-first-served basis. However, in the event of large number of applicants for a course, additional course(s) can be arranged. Please contact the training centre for booking your seat. You may also fill up the Registration form and submit to the training centre.
Assessment of participants will be carried out by observation and written tests. A participant will be considered as successfully completed a course on scoring overall 60% marks in the assessment tests and 80% attendance and will receive a Certificate of acknowledgement. Remaining participants will receive a participation certificate.