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Advanced Industrial Pneumatics Training Course (MP-10005)

Course Length: 16 hours

Purpose: This course provides comprehensive discussion of the applications of Advanced Industrial Pneumatics (MP-10005) as they apply to pneumatic systems. Hands-on training is accomplished through the use of component cutaways and tabletop trainers.

This process allows the students to see pneumatic systems in action and to perform setups of pneumatic circuits. This course is taught by highly qualified instructors who are experts in this field. The course covers basic industrial pneumatics including theory, component operation, and pneumatic power circuits.

This course is recommended for personnel involved in the basic maintenance and repair of pneumatic equipment.

Objectives: Upon completion of this course and with the use of the training manual, students will be able to:

  • Describe pneumatic power and the components used in the design of pneumatic systems.
  • Identify and explain common pneumatic components.
  • Describe basic pneumatic theory.
  • Replace hoses, seals, and fittings according to the guidelines identified in this training course.
  • Explain common circuit applications.
  • Describe preventive maintenance actions such as removing, replacing, and cleaning common pneumatic components.
  • Interpret ANSI symbols and drawings to explain the functions of specific pneumatic systems.
  • Troubleshoot common pneumatic components.

Table of Contents

Introduction 1-1
Objectives 1-1
Industrial Safety 1-1
Accidents 1-2
Near-Accident 1-2
Accident Prevention 1-2
The People Factor 1-3
Lessons Learned 1-3
Stored Energy System Safety 1-3
Locking Out 1-4
Restoring System Integrity 1-4
Summary 1-5

Introduction 2-1
Objectives 2-1
Pneumatic Theory 2-1
Compressibility and Expansion of Gases 2-11
Boyle’s Law 2-11
Charles’ Law 2-13
General Gas Law 2-14
Work and Energy 2-15
Minimizing Friction 2-23
Pneumatic Symbols 2-25

Introduction 3-1
Pressure Regulators 3-1
Valves (Nondirectional Control) 3-6
Manually Operated Valves 3-6
Check Valves 3-9
Solenoid-Operated Valves 3-11
Directional Control Valves 3-15
Control Valve Element 3-16
Two-Way Valves 3-17
Three-Way Valves 3-18
Four-Way Valves 3-19
Five-Way Valves 3-28
Installation Requirements 3-28
Flow Controls 3-28
Meter-in 3-32
Meter-out 3-32
Intensifier 3-32
Cylinders/Actuators 3-33
Ram-Type Cylinders 3-33
Piston-Type Cylinders 3-35
Cushioned Cylinders 3-39
Motors and Compressors 3-39
Limited Rotation Actuators 3-54
Purification Equipment 3-56
Preliminary Filters 3-60
Moisture Removal/Drying 3-62
Lubricators 3-65
Piping and Connectors 3-79
Rigid Piping 3-81
Semirigid (Metallic Tubing) 3-82
Tube Fittings 3-84
Hoses 3-86
Sealing Devices 3-87
Materials 3-88
Seal Designs 3-89
Wipers and Backup Washers 3-93
Receivers 3-99
Summary 3-105

Introduction 4-1
Basic Pneumatic System 4-1
Sample Schematics 4-2
Basic Workstation 4-2
Advanced Workstation 4-3
Multimode Circuit 4-5
Determining Causes of Failures 4-6
Understanding the System 4-7
Troubleshooting Procedures 4-7
Locating Troubles 4-7
Operating Manuals 4-8
Checking Supply Systems 4-9
Troubleshooting an Actuator 4-9
Checking a Control Valve 4-10
Checking a Control Valve Actuator 4-11
Making Final Adjustments 4-13
Pneumatic System Troubleshooting 4-13
Common Causes of Failure 4-13
Dirt 4-13
Misapplication 4-14
Maintenance 4-15
Improper Design or Installation 4-15
Summary 4-16

Appendix A — Pneumatic Lab Exercises A-1
Lab Exercise 1: Trainer Familiarization
Lab Exercise 2: Pressure Regulators
Lab Exercise 3: Needle (Throttle) Valves
Lab Exercise 4: Flowmeters
Lab Exercise 5: Solenoid Directional Controls
Lab Exercise 6: Air Piloted Directional Control Valves
Lab Exercise 7: Air Line Lubrication
Lab Exercise 8: Air Filtration
Lab Exercise 9: Venturi Vacuum Generators
Lab Exercise 10: Pneumatic Cylinders

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