Lesson 1Pump types (gear, vane, piston): characteristics, efficiencies, and selection criteria for 5–25 l/min and up to 160 barThis section compares gear, vane, and piston pumps for small to medium flows, covering efficiencies, noise, suction limits, and selecting displacement and speed for 5–25 l/min at up to 160 bar with suitable lifespan.
External vs internal gear pump featuresVane pump efficiency and noise behaviorAxial piston pumps and control optionsSizing displacement for flow and speedNPSH, suction limits, and inlet conditionsLesson 2Seals, fittings, and connectors: selection for mineral oil, pressure ratings, and leak minimisationThis section focuses on seals, fittings, and connectors for mineral oil systems, explaining seal materials, pressure ratings, thread standards, and assembly practices to minimise leakage, weeping, and installation damage.
Seal materials for mineral oil compatibilityStatic vs dynamic sealing arrangementsThread types: BSPP, NPT, and metricO-ring groove design and surface finishTorque, assembly, and leak testingLesson 3Directional control and flow control valves: solenoid vs manual valves, proportional considerations, and spool choicesThis section explains directional and flow control valves, comparing manual, solenoid, and proportional options, including spool symbols, flow ratings, pressure drops, and choosing valve response for each circuit.
Manual vs solenoid operated valve choicesSpool symbols, center options, and leakageProportional valves and control electronicsFlow control valves: fixed vs adjustableValve sizing for flow, pressure, and dutyLesson 4Reservoir design: sizing rules, breathers, sight gauges, baffles, and settling time calculationThis section covers reservoir sizing, layout, and accessories, including volume rules, baffle design, settling time, and specifying breathers, sight gauges, and clean-out features for cooling, de-aeration, and maintenance.
Tank volume rules and return residence timeBaffle layout for de-aeration and coolingBreathers, filters, and moisture controlSight gauges, level switches, and alarmsDrain ports, clean-out covers, and slopesLesson 5Motor selection: matching electric motor power, starting torque, and service factor to pump loadThis section links hydraulic pump demand to electric motor selection, covering power calculations, starting torque, service factor, duty class, and starting methods to prevent nuisance trips and overheating.
Calculating hydraulic power and motor kWStarting torque vs pump breakaway torqueService factor and duty cycle selectionStar-delta and soft starter implicationsMotor enclosure, cooling, and environmentLesson 6Pressure control elements: relief valves, sequence valves, pressure reducing valves — selection and setpoint approachesThis section explains pressure control elements like relief, sequence, and pressure reducing valves, covering internal layouts, stability, sizing, and methods for setting and verifying safe, repeatable pressure limits.
Direct vs pilot operated relief valvesSetting main relief valves safelySequence valves for staged operationsPressure reducing valves and circuitsPressure override, stability, and chatterLesson 7Filtration strategy: return-line vs pressure-line vs tank suction filters; micron ratings and contamination codes (ISO 4406)This section compares return-line, pressure-line, and suction filtration, explaining usage, micron ratings, and interpreting ISO 4406 contamination codes to meet cleanliness and warranty requirements.
Return-line vs pressure-line filter applicationsTank suction strainers and protection limitsMicron rating, beta ratio, and dirt holdingReading and applying ISO 4406 codesFilter sizing, pressure drop, and service lifeLesson 8Shut-off valves, non-return valves, and drain/check valves: types, materials, and placementThis section details shut-off, non-return, and drain or check valves, explaining types, materials, leakage behaviour, cracking pressure, and placement for safe isolation, backflow prevention, and controlled draining.
Ball, gate, and needle shut-off valve usesCheck valve cracking pressure and sizingPilot-operated check valves for load holdingMaterial choices for corrosion and fluid typeDrain and bleed valves for safe maintenanceLesson 9Instrumentation: pressure gauges, temperature sensors, flow meters — selection and mounting pointsThis section covers selecting and placing pressure, temperature, and flow instruments, including accuracy classes, damping, protection, and best mounting points for commissioning, troubleshooting, and monitoring.
Pressure gauge types and accuracy classesGauge snubbers, isolators, and overpressure limitsTemperature sensor types and immersion rulesFlow meter technologies and selectionPermanent vs test-point instrumentation
