Basic Industrial Pneumatics Training Course (MP-10004)

Course Length: 8 hours

Purpose: This course provides comprehensive discussion of the applications of Basic Industrial Pneumatics (MP-10004) as they apply to pneumatic systems. This course is delivered in a format that uses a combination of classroom lecture coupled with a comprehensive component review using real-world products.

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 circuits.

This course is recommended for personnel involved in the basic maintenance 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.
• Explain common circuit applications.
• Describe basic preventive maintenance actions.
• Interpret ANSI symbols and drawings to explain the functions of specific pneumatic systems.
• Troubleshoot basic pneumatic components.

Table of Contents

1. OVERVIEW
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

2. PNEUMATIC POWER THEORY
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

3. FLUID SYSTEM COMPONENTS
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

4. PNEUMATIC CIRCUITS
Introduction 4-1
Basic Pneumatic System 4-1
Sample Schematics 4-2
Troubleshooting Procedures 4-7
Locating Troubles 4-7
Checking a Control Valve 4-10
Common Causes of Failure 4-13
Dirt 4-13
Misapplication 4-14
Maintenance 4-15
Improper Design or Installation 4-15
Summary 4-16