Hydraulic Systems Maintenance

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The program covers a variety of issues related to the arrangement of the hydraulic service work and ensuring the hydraulic systems reliability.

Purpose:

Familiarize participants with the principles and experience in building a hydraulic systems maintenance system

General Description:

The course will cover in details the various aspects of the hydraulic systems reliability assurance system

Who is this training for:

Chief mechanics, engineers of the hydraulic maintenance services.

Program:

1.  Introduction

  • Introduction to the power hydraulic drive and industrial hydraulic automation
  • Energy conversion in power hydraulics and hydraulic automation systems
  • Principal physics of hydraulics
  • Hydraulic system standard structure
  • Power hydraulic centers, controllers, directional equipment, condensing and driven equipment
  • General issues of ensuring the hydraulic systems reliability
  • Basic principles of ensuring reliability of hydraulic drive equipment, centralized and circulating lubrication systems

2. General Principles

  • General principles of control arrangement over the technical condition, maintenance and repair of the hydraulic equipment
  • Overview: from time-based maintenance of the hydraulic systems to the precision predictive maintenance
  • Beginning of the journey, initial audit of the hydraulic systems – content, goals, focus, review of the initial audit results of the hydraulic systems, their operation system, and maintenance
  • Identification of the priority areas, goals and tasks of a practical work

3. Arrangement of the system maintenance and repair of the hydraulic systems equipment, centralized and circulating lubrication systems

  • The regulatory framework of the audit. Typology of problems identified during the audit of hydraulic systems
  • Incidents analysis of occurence time, equipment, root causes, etc.
  • Tasks that require solutions. Setting priorities and finding solutions
  • Tasks performed by the specialized departments. Maintenance breakdown by common, special, and precision
  • Defining areas of responsibility and competence, practicising the interaction system
  • Goals, metrics, procedures and strategies

4. Areas of competence for the hydraulic service specialists, servodrives and proportional

  • Performed functions, areas of responsibility, serviced systems, repaired and diagnosed equipment
  • Methods and techniques
  • Development trends

5. Areas of competence for the lubrication service specialists

  • Performed functions, areas of responsibility, serviced systems, repaired and diagnosed equipment
  • Methods and techniques
  • Development trends

6. Arrangement of power fluids (PF) and lubricants (L) condition monitoring

  • The system of the power fluids (PF) and lubricants (L) condition monitoring . Ageing and contamination of the PF and the L. Procedures and criteria for monitoring their current state
  • Controlled parameters and target quality levels of the PF and L
  • Types, methods and applied means of monitoring the current state of PF and oils:organoleptic monitoring, built-in check. Cavitation risks and their prevention
  • Incoming control of PF and L. Laboratory methods of monitoring the oils state – procedures, instruments and tools, reporting and interaction system
  • Review the strategies related to the PF and oils

7. Experience in solving problems related to the quality of PF and L

  • Strategies, procedures, methods and means of maintaining the required level of PF, oils and L quality
  • Process structure and the services interaction. Zones of responsibility for the PF, oils and L quality
  • Basic rules for the use, storage, and disposal of PF, oils and L
  • Warehousing arrangement. Standards of oil storage
  • 8. Prevention of contamination when replacing and topping up the PF and oil
  • Arrangement of PF and L replacement and topping up
  • Procedures, equipment and the tools for the PL and oils filling. Overview and application practice

9. Prevention of equipment failures due to PF and L contamination

  • Practice in the application of system filtration and dehydration, an overview of the methods and the system filtration equipment
  • Prevention of flooding and contamination of systems
  • Overview of possible strategies

10. Prevention of equipment failures due to PF and oil contamination ingressed into the system during repairs

  • Preparation and organization of the workspace at the existing production facilities during maintanece of lubrication and hydraulic systems
  • Procedures and measures to prevent the contamination during the works execution. Overview of possible strategies
  • Practice of systems washing. Application of the additional circulatory cleaning loop after the major repairs and oil changes in the systems
  • Preparation and organization of the workspace, arrangement of work on repair of hydraulic drive equipment units and assembly units in the service workshop. Receiving, storing and incoming quality control of new and rebuilt spare parts and components
  • Procedures and experience in processing and optimizing the spare parts set necessary to ensure reliable operation of hydraulic systems

11. Features of operation and reliability ensurance of hydraulic power centers

  • Basic principles of ensuring the reliability and safety of hydraulic centers and condensing equipment

12. Features of operation and reliability assuarance of seals, HP hoses and pipelines of hydraulic and lubrication systems

  • Basic principles of ensuring the reliability and safety of HP hoses and pipelines
  • Ensuring the reliability of seals
  • Operator’s responsibility for the reliability and safety of HP hoses, pipelines, seals, etc.

13. Features of operation and reliability assurance of control, regulating and safety equipment

  • The main types of malfunctions and their prevention. Seals issues
  • Issues of current monitoring and diagnostics of hydraulic systems
  • The need to introduce modern advanced methods and controls

14. Features of operation and reliability assurance of linear and rotary drive systems

  • Basic principles of ensuring the reliability and safety of linear and rotary drive equipment (hydraulic motors and hydraulic cylinders)

15. Reliability assurance features of centralized and circulating lubrication systems

  • Experience in operation, maintenance and repair. The main types of malfunctions, their diagnostics and prevention
  • Overview of strategies and best practices on maintenance and repair of equipment for centralized and circulating lubrication systems

16. Predictive maintenance of power hydraulics and lubrication systems

  • Modern methods of monitoring and diagnostics of the technical condition of hydraulic equipment and lubrication systems
  • Controlled parameters
  • Parametric control with a high resolution level, archiving of working trends and analysis of trend dynamics, remote control by means of automated dispatch control systems (DCS) and PCS

17. Safety requirements to the operation, maintenance and repair of hydraulic systems,hydraulic automation and centralized lubrication systems

  • Hazards and risks during the operation, maintenance and repair of hydraulics and lubrication systems
  • Main requirements for ensuring reliability and safety.
  • Reliability and safety standards
  • Brief introduction to ISO 4413 and related GOST Standards

18. Analysis of hydraulic and lubrication services perfromance

  • Performance evaluation system
  • Indicators, criteria/metrics