EDUCATION

RECOMMENDATIONS

QUALIFICATIONS ASSOCIATED
WITH FLUID POWER SYSTEMS

IMPLEMENTATION OF CETOP EDUCATION

RECOMMENDATIONS IN EUROPE

CETOP QUALIFICATIONS APPROVED

CENTRES GUIDELINE

APPENDIX: CETOP QUALIFICATIONS

APPROVED CENTRES GUIDELINE

HYDRAULICS PROGRAMMES
(H1), (H2, MH2, IH2), (H3, MH3, IH3)
CETOP Passport Occupational Level 1-3

PNEUMATICS PROGRAMMES
(P1, P2, P3)
CETOP Passport Occupational Level 1-3
No part of this publication may be photocopied or otherwise reproduced
without the prior permission in writing of the Association. Whilst the
Association does its best to ensure that any information that it may give
is accurate, no liability or responsibility of any kind is accepted in this
respect by the Association, its members, its servants or agents.
2
 3

CONTENTS

QUALIFICATIONS ASSOCIATED WITH FLUID POWER SYSTEMS

RE 2015/06.02- H/P page 4
CETOP EDUCATION RECOMMENDATIONS IN EUROPE

RE 2015/06.02- H/P page 12

CETOP QUALIFICATIONS APPROVED CENTRES GUIDELINE

RE 2015/06.02- H/P page 15

APPENDIX: CETOP QUALIFICATIONS APPROVED CENTRES GUIDELINE

Appendix RE 2015/06.02- H/P page 21

HYDRAULICS PROGRAMMES page 41

POWER HYDRAULICS PROGRAMME (H1): RE 2015/06.01 - H

CETOP (Passport) Occupational Level 1 page 43

HYDRAULICS & ASSOCIATED CONTROL PROGRAMME (H2): RE 2015/06.01 - H

CETOP (Passport) Occupational Level 2 page 47

MOBILE HYDRAULICS PROGRAMME & ASSOCIATED CONTROL (MH2): RE 2015/06.01 - H

CETOP (Passport) Occupational Level 2 page 52

INDUSTRIAL HYDRAULICS & ASSOCIATED CONTROL PROGRAMME (IH2): CETOP RE 2015/06.01 - H

CETOP (Passport) Occupational Level 2 page 57

HYDRAULICS & ASSOCIATED CONTROL PROGRAMME (H3): RE 2015/06.01 - H

CETOP (Passport) Occupational Level 3 page 62

MOBILE HYDRAULICS & ASSOCIATED CONTROL PROGRAMME (MH3): RE 2015/06.01 - H

CETOP (Passport) Occupational Level 3 page 71

INDUSTRIAL HYDRAULICS & ASSOCIATED CONTROL PROGRAMME (IH3): RE 2015/06.01 - H

CETOP (Passport) Occupational Level 3 page 80

PNEUMATICS PROGRAMMES page 88

PNEUMATICS PROGRAMME (P1): RE 2015/06.01 - P

CETOP (Passport) Occupational Level 1 page 90

PNEUMATICS PROGRAMME (P2): RE 2015/06.01 - P

CETOP (Passport) Occupational Level 2 page 94

PNEUMATICS & CONTROL PROGRAMME (P3): RE 2015/06.01 - P

CETOP (Passport) Occupational Level 3 page 99
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QUALIFICATIONS
ASSOCIATED WITH FLUID POWER SYSTEMS
RE 2015/06.02- H/P
1. INTRODUCTION • PLANNING AND PREPARING
• INSTALLING
1.1 What is CETOP? • COMMISSIONING
• TESTING
Founded in 1962, CETOP is the European Oil • MAINTAINING
Hydraulics and Pneumatics Committee and repre- • FAULT DIAGNOSIS AND RECTIFICATION
sents the National Fluid Power Associations within • REMOVAL AND REPLACEMENT
the seventeen European countries, inturn represen- • DISMANTLING AND REASSEMBLING
ting some 1,000 companies throughout Europe.
To carry out these tasks at the various “occupa-
CETOP supports, promotes and provides aid to tional levels” and achieve a level of performance
the fluid power industry and prepares standards and repeatability within a given time will require
and guidelines in co-operation with the technical that person to be COMPETENT.
committees of ISO (International Organization
for Standardization), CEN (European Committee A “Competence Based Qualification” will therefore
of Standardization) and the various National consist of a combination of both knowledge and
Standards Organizations. application of the knowledge, supported by
practical experience in the workplace.
More detailed information may be obtained by
visiting the CETOP web-site at www.cetop.org.
1.5 OCCUPATIONAL LEVELS - VS
1.2 Education and Training Proposal and KNOWLEDGE BASED/COMPETENCE
Harmonization initiative for Europe BASED PROGRAMMES OF STUDY TO
With the ever-growing need throughout Europe MEET THE OCCUPATIONAL NEEDS
and the world for a COMPETENT, WELL The following provides an example to enable the
EDUCATED WORKFORCE, able to maintain reader to clearly see the difference in knowledge
and manage fluid power systems; CETOP based levels under consideration.
have developed a programme that harmonies
to the qualifications of such a workforce. A relief valve is used as the example and this
ANOLOGY outlines the difference in knowledge
1.3 The Aim requirements at the various levels and clearly
The aim is to develop an acceptable and agreed indicates where training and experience plays
structure of “Competence Based Qualifications” re- its part.
flecting the needs of those people who fall into the
categories covered by OCCUPATIONAL LEVELS RELIEF VALVE
1, 2 and 3 (see 2.1). Such a structure will reflect the At Level 1- the candidate needs to know
needs of those people in employment or being what a relief valve is, what it does and why.
prepared for a particular level of employment. (Basic Function.)

1.4 What are COMPETENCE BASED At Level 2 - the candidate needs to know in
QUALIFICATIONS? addition to the above, how the relief works.
Historically, many people have achieved a qualifi- (Function and Operation.)
cation that represents a “level of academic
attainment” and does not always relate to that At Level 3 - the candidate also needs to know
person’s ability to apply their knowledge to a “real the different applications that a relief valve can
life situation”. be used for (unloading, proportional control)
The real life skills associated with Maintenance and what can go wrong. (Function, Operation,
and Management of fluid power systems are Application and Technical Specification.)
work related and are as follows:

No part of this publication may be photocopied or otherwise reproduced without the prior permission in writing of the Association.
Whilst the Association does its best to ensure that any information that it may give is accurate, no liability or responsibility of any kind is accepted in this respect by the Association,
its members, its servants or agents. Further copies of this document can be obtained from the CETOP, e-mail: [email protected]. PDF-version of this document can be
obtained from the CETOP web-site: www.cetop.org.
 5

From base level to Level 1 requires only From Level 2 to Level 3, a greater depth and
education and training, work-based activities will breadth of knowledge is required compared to
be repetitive, following established procedures level 2, with a knowledge of other subject areas
and requires very little experience and knowledge complementary to fluid power. At level 3, the
of other areas. competence-based skills should clearly reflect a
level of experience able to deal with the broader
From Level 1 to Level 2 requires education and more complex range of activities required to
and training with an acquired level of fulfil this occupational level.
competency allied to experience to meet Level
2 Occupational requirements.

2. COMPETENCE IN FLUID POWER SYSTEMS

2.1 OCCUPATIONAL LEVELS

LEVEL 1 This person will perform activities that follow an established procedure. Activities
will be recurring and of a short term nature. The reaction to most problems will be to
summon help or follow a predefined set of actions.

LEVEL 2 This person will perform a variety of activities and needs understanding of the technical
factors involved. The activities may require the interpretation and application of varied
and non routine specifications. Activities will involve the use of simple diagnostic
checks and ability to make a positive response to deviations. Co-operation with others
in team or work groups may be required.

LEVEL 3 This person will be involved in a broad and often complex range of activities,
often requiring independent decisions to be made on technical matters
concerning specifications, resources or processes. Planning of work will be a
responsibility as will the finding and rectification of faults. Responsibility for the
quality of work undertaken and the required outcomes are also included.
6

2.2 Knowledge based and competence based skills

KB CB KB CB KB CB

COMPONENTS L1 L2 L3

• types ● ● ●

• construction ● ●

• function ● ● ●

• operation ● ●

• application ● ●

• performance/characteristics ● ●

• selection/recommendations ● ● ● ●

• sizing ● ● ● ●

• mounting/interface ● ● ● ●

• control systems/interface ● ● ● WSD

• installation ● ● ● ● ● ●

• commissioning/setting up ● ● ● ● ● ● WSD

• malfunction and effects ● ● ●

• testing ● ● ● ● WSD
• fault diagnosis ● ● ● ●

• removal and replacement ● ● ● ● ● ●

• dismantle ● ● ● ●

• re-assemble ● ● ● ●

• contamination tolerance/awareness ● ● ●

• technical data ● ●

• use of formulae/calculations ● ●

• system design/compatibility ●

• safety precautions/features ● ● ●

• risk assessment/use ● ● ●

• physical attributes (noise etc.) ● ● ●

• legislation/directives/standards ● ●

KNOWLEDGE BASED = KB · COMPETENCE BASED = CB · WITHIN THE SCOPE OF THEIR DUTIES = WSD
NOTE- although the O may appear in a number of levels, the breadth and depth of the subjects differ from level to level
 7

KB CB KB CB KB CB
SYSTEMS L1 L2 L3
• planning- projects/actions ● ●

• technical data/specifications ● ● ● ●

• circuit diagrams ● ● ● ● ● WSD

• control systems/options ● ●

• control system interfaces ● ●

• configuration ● ● ●

• operation ● ● ●

• application ● ● ●

• installation (parts and whole) ● ● ● ●

• commissioning ● ● ●

• modifications ●

• recommendations for improvement ● ●

• health monitoring (con: monitoring) ● ● ● ●

• performance monitoring (ditto) ● ● ● ●
(procedures and use of diagnostics)
• interpretation of results ●

• routine maintenance ● ● ● ● ● ●

• proactive/predictive maintenance ● ● ● ●

• contamination management/control ● ● ● ● ● WSD

• fault diagnosis ● ● ● ●

• fault rectification ● ● ● ●

• fault-cause analysis ● ● ● ● WSD

• corrective actions ● ● ● ●

• safe working procedures ● ● ● ● ● ●

• re-commissioning procedures ● ● ● ●
• hydraulic and compressed air ● ● ● ● ●
fluid (management/selection)
• risk management ● ●

• legislation/directives/standards ● ●

KNOWLEDGE BASED = KB · COMPETENCE BASED = CB · WITHIN THE SCOPE OF THEIR DUTIES = WSD
NOTE- although the O may appear in a number of levels, the breadth and depth of the subjects differ from level to level
8

KB CB KB CB KB CB

CORE SKILLS/Knowledge L1 L2 L3

• fundamental PRINCIPLES ● ● ●

• use of formulae and calculations ● ●

• technical report writing ● ● ● ● WSD

• communications ● ● ● ● ● ● WSD
• information technology ● ● ● ● ● ● WSD

• presentation skills ● ●

• planning skills ● ● ● ● ● ● WSD

• preparing procedures/work instructions ● ●
• reading and interpretation technical data/ ● ● ● ● ● ● WSD
circuit diagrams
• translation of information ● ● ● ● WSD
• analysis of facts ● ● ●

• organizational management ● ● ●

• quality management ● ● ●

• safety management ● ● ●

• power and motion control interfaces ● ● ● WSD

KNOWLEDGE BASED = KB · COMPETENCE BASED = CB · WITHIN THE SCOPE OF THEIR DUTIES = WSD
NOTE- although the O may appear in a number of levels, the breadth and depth of the subjects differ from level to level
 9

2.3 TECHNICAL TERMS USED Relating to COMPONENTS

Type Different components used within a system, e.g. gear pumps, vane pumps, piston
pumps, screw compressor, vane compressor, lubricators, dryers, coolers etc.

Construction Individual design attributes, e.g. a pump may have a splined shaft, a relief
valve may be sub-plate mounted, compressors fully packaged, cushioned
cylinders
Function Purpose or specific activity, e.g. the function of a relief valve is to limit the
pressure to a particular level, 3port-2position valve to operate single acting
cylinder.
Operation Specific performance, e.g. a relief valve poppet lifts off its seat when the
system pressure creates a force upwards, greater than that of the downward
force of the opposing spring.

Application Relates to the function of a component within a circuit or system, e.g. a pressure
reducing valve may be used to specifically limit the pushing force on a small press
cylinder.
Performance/ Refers to the dynamic operation of a component, e.g. pressure override of a pres-
characteristic sure control valve, slippage rate of a pump, pressure drop across a proportional
directional control valve. FAD for a compressor, pressure drop in pipes.

Selection/ Types and choice available and why a particular component would be selected in
recommendation preference to another.

Sizing Relating to range and capacity, e.g. flow and pressure range to meet a specific requirement.

Mounting/interface

Control System/ Pilot operation solenoid operation, ‘on-off’ or interface proportional, digital or
Interface analogue, solenoid/pilot, detent.

Procedures to be followed when fitting a component into a system or part

Installation
of a system, new or replacement.

Commissioning Procedures to follow to meet a required performance specification, e.g. setting up

/setting up of a compensator on a pump to 150 bar. Speed of a cylinder and cushioning

Malfunction and Refers to deviation in performance, possible causes and the effect on
effects the system.

Testing Checking the settings of a component meet a specific

performance (involving diagnostic equipment).

Fault diagnosis Following procedures to identify a fault against specific symptoms, evaluation
of the facts to identify a cause and implementation of a solution to rectify and
pre-vent a re-occurrence.

Removal/ Procedures to be followed, including safe working practices and the correct use
replacement of tools and equipment. Compliance with all specifications and manufacturer
recommendations.

Dismantle Procedures to be followed, including the correct use of tools and equipment,
following safe working practices and compliance with manufactures
recommendations and specifications.
10

Re-assemble Procedures to be followed, including the correct use of tools and

equipment, following safe working practices and compliance with
manufactures recommendations and specifications.

Contamination Refers to manufacturers cleanliness recommendations for components to

tolerance/ effectively perform, plus knowledge of target cleanliness levels and methods
awareness of achieving and maintaining them.

Technical data Refers to manufacturers catalogue information and recommendations specific to

a particular component.

Use of formulae/ Refers to fundamental formulae to determine information specific to

calculations component size, performance, flow rate, pressure drop, etc.

System design/ Refers to a component’s performance characteristics, size, construction,

compatibility etc. to meet a system specification in conjunction with other components.

Safety precautions/ Refers to specific component safety features and/or the safety precautions to
features be taken when a particular component becomes part of a system.

Risk Refers to the investigation of a component within a system to identify any

assessment/use possible safety hazards during use and the necessary
recommendations/precautions to be implemented.

Physical attributes Refers to noise, heat generation, vibration (belonging to or caused by).

Legislation/ European Standards, ISO Standards, Health & Safety requirements and
directives/ directives, Machinery Directive. Specific links to component application in
standards a particular system.

TECHNICAL TERMS USED Relating to SYSTEMS

Planning - projects/ Preparing a documented plan of actions relating to a specific task involving:
actions • Procurement • Compliance • Staffi ng/resourcing • Time-based action plan • Review/
evaluation • Installation/commissioning • Hand-over/declaration of conformance

Technical data/ Use of manufacturers catalogues and data sheets with reference
to recommendations for ‘setting up’, installation and testing.
specification
Circuit diagrams Symbolic representation of components and systems to meet
the required ISO specification.

Control systems/ Open and closed loop (continuous and discontinuous), digital and/or
options analogue options, pump control system options.

Control system Digital and analogue systems (use of PLC’s and bus systems, pilot control).
Interfaces

Configuration Open systems, closed hydrostatic transmission system. (List of specific

circuits relating to a particular application).

Operation Specific performance at system level (involving a number of components).

Application Specific system function (operational specification).

 11

Installation Procedures to be followed when configuring a system from

individual components (involving planning and preparation).

Commissioning Preparing a system for ‘active duty’, setting up of the component parts to
meet a performance specification.
Modification Procedures to be followed when alterations are made to a system for example,
the need to update technical documentation and the performance specification
to ensure that any modifications are in compliance with the manufacturers
specification and all requirements to health and safety.

Recommendations Reports relating to system improvements specific to a particular aspect of its

for improvement performance, maintenance safety and operational management.

Health (condition)
Monitoring
levels • Noise and vibration • Temperature • General leakage • Documentation & report

Performance Procedures set up to determine that system and component performance

Monitoring meets the required operation specification with reference to: • Pumps – Q/P
testing • Actuator speeds • Operational pressures • Documentation & report
Interpretation Referring to health and performance monitoring, translating results into an
of results action plan with clear ‘outcome objectives’ as part of the proactive maintenance
programme.
Routine Maintenance activities that are time based – daily, weekly, monthly etc.
maintenance and follow a ‘set checklist’ approach.
Pro-active/predictive Maintenance activities carried out as part of a plan for
maintenance continued improvement and/or relating to specific condition
monitoring.
Contamination Refers to that of maintaining cleanliness levels that meet the TARGET CLEANLI-
management/ NESS LEVEL and ensuring that procedures are in place to achieve and maintain
control this at all times. Where a non-compliance is identified, procedures should be in
place to enable remedial action to be taken and cause to be evaluated.

Fault diagnosis Procedures to be followed, to effectively diagnose a fault within a system.

Fault rectification Procedures to be followed, to effectively rectify a fault with a system and
to re-establish the system to a fully operational status.
Fault-Cause- Management procedures in place to investigate the cause of a fault and the
Analysis necessary steps to implement preventative measures against a re-occurrence.

Corrective actions A report outlining actions to be taken to overcome and prevent the re-occurrence of a fault
or that of fault prevention identified as part of the programme for continued improvement.

Re-commissioning Plan of action inline with manufacturers recommendations and operational/

Procedures technical specifications for the system to become fully operational.

Fluid Management/ Refers to control procedures relating to:

Selection • Oil procurement, storage, transportation, filling and dispensing systems whilst in
and Treatment use in the machine to final disposal with regard to all aspects of health and safety.
• Compressed air, contaminants and purity classes with regard to all aspects.

Risk Refers to the investigation of a system by a competent person to identify any

possible hazards during use and the necessary
recommendations/precautions to be implemented to prevent danger to all

Legislation/ European Standards, ISO Standards, Health & Safety requirements

directives/standards and directives, Machinery Directive. Specific links to systems and their
application.
12

IMPLEMENTATION OF CETOP
EDUCATION RECOMMENDATIONS IN
EUROPE CETOP RE 2015/06.02 - H/P

1. THE OUTCOME sure that all aspects of scheme quality assurance,

validation and verification are maintained against
This initiative will enable employers to identify the CETOP RECOMMENDATIONS.
levels of competence, skills and knowledge
achieved by a person holding a CETOP This guideline provides recommendations for
Qualification and will provide a greater guarantee achieving CETOP Qualifications including an
of quality assurance throughout. explanation of competence based qualifications
and the methodology associated with their
The proposal is for CETOP Qualifications to acquisition.
become the “bench mark” for fluid power edu-
cation and training throughout Europe; whilst at The intention is for each CETOP ASSOCIATION
the same time providing greater opportunities for MEMBER to achieve within their own
employment and skills transfer within Europe. educational systems the required outcomes,
giving each organization total flexibility and
freedom to develop and implement the
2. HOW WILL THIS BE MANAGED? necessary routes for achievement.

Association members will also be responsible for

The responsibility to implement and manage recommending and endorsing training organi-
this harmonization programme will be that of the zations to deliver this proposal and assist
individual CETOP ASSOCIATION MEMBERS. through their member companies in providing
and supporting the necessary resource.

It is recommended that each member works Each CETOP ASSOCIATION MEMBER will
closely with the various education and training or- award the necessary certificates recognizing an
ganizations within their respective countries to en- “individual’s level of achievement”.

3. PROPOSED MODEL FOR IMPLEMENTATION OF CETOP QUALIFICATIONS

CETOP Recommended centres Each CETOP Member Association

see graphs 2 and 3

Identifies, approves and works closely with the

necessary Education and Training Establishments
to develop, deliver, administer and assess the
Competence Based Programmes.
VOCATIONAL
OCCUPATIONAL
LEVELS 1, 2 AND 3
LEVEL 1
LEVEL 2
LEVEL 3

To meet the requirements of candidates at, or on route to.

Note: CETOP fully support and encourage practical work based assessments assuming all
necessary evidence criteria can be met.

No part of this publication may be photocopied or otherwise reproduced without the prior permission in writing of the Association.
Whilst the Association does its best to ensure that any information that it may give is accurate, no liability or responsibility of any kind is accepted in this respect by the Association,
its members, its servants or agents. Further copies of this document can be obtained from the CETOP, e-mail: [email protected]. PDF-version of this document can be
obtained from the CETOP web-site: www.cetop.org.
 13

The certificate will then be endorsed by a clear a) their present knowledge, skills, experience and
indication of the respective CETOP whether employed or unemployed
QUALIFICATION LEVEL achieved. This certifi- b) the expectations of their employer relating to
cate will then represent a recognized qualification their position of employment or specialized
throughout Europe. skills level required (Example, a University
graduate electronic person may only need to
4. INDIVIDUAL RECORDS OF ACHIEVEMENT know a little about hydraulics and a level 1
programme may satisfy his or her needs)
Through their period of study and acquisition of
competence based skills, all candidates will be Recognized Centres must provide equal opportuni-
expected to maintain their own individual ties to candidates at all levels and provide a
RECORDS OF ACHIEVEMENT. This should form variety of learning opportunities, ranging from that of:
a portfolio of evidence covering both knowledge
and competence based skills achieved, apper- • Short Courses and Modules
taining to their particular occupation level. All • Flexible Distance Learning Programmes
such records must carry a signature of • Personal Study
authenticity and become the basis for “continued
professional development”.
6. CONCLUSION

5. PROVIDING THE CORRECT LEVELS OF For this “Harmonization Initiative” to be successfully

EDUCATION AND TRAINING TO MEET BOTH implemented and to be successful and effective, it is
INDIVIDUAL AND ORGANISATIONAL NEEDS necessary for all CETOP ASSOCIATE MEMBERS to
establish within their own countries, a series of
It will be the responsibility of the “Recommended competence based programmes, covering the
Centeres” to provide advice and direction relating various levels and associated subjects. They must
to individual needs, whilst taking into consideration work closely with educational establishments,
their prior knowledge and experience. industry lead bodies, OEM’s and end users to
It does not always follow, for example, that an “oc- ensure that the content continuously meets their
cupational level 3 person” is capable of dealing with needs, in light of changes in occupational standards
a level 3 programme of study. Consideration should and ever changing technology.
be given to “programme profiling” to enable
candidates to proceed successfully to the required Relating to “Recommended Centres”, CETOP
levels. Different people will require different Member Associations must play an active role in
breadths and depth of knowledge and associated establishing, implementing and verifying all quality
competence based skills depending upon: assurance procedures necessary to ensure
“Parity” and standardization throughout.

GRAPH 1: COMMON ACCORD (EUROPEAN NETWORK)

BELGIUM (FIMOP)

UNITED KINGDOM (BFPA) CZECH REPUBLIC

GERMANY (VDMA) POLAND (CORPORATION)

SPAIN (AIFTOP) CETOP FRANCE (UNITOP)

RECOMMENDED
CENTRES ASSESSING
ITALY (ASSOFLUID) NORWAY (HPF)
CANDIDATES
AT LEVELS 1, 2, AND 3
NETHERLANDS (FEDA) SLOVENIA (FTS)

SWITZERLAND(SWISSMEM/GOP) FINLAND (FHPA)

SWEDEN (HPF) TURKEY

ROMANIA (FLUIDAS)
14

GRAPH 2: CETOP RECOMMENDED

CETOP
Approved by

Association
CENTRES

Must have:

Competent /Experienced qualified staff carried out by

external verifier
systems and associated

Management systems for records and

Quality control and Safety Policies

Equal Opportunity Policy

GRAPH 3: RECOMMENDED ASSESSMENT METHODS

ASSESSMENT METHODS FOR

COMPETENCE BASED QUALIFICATIONS

“Knowledge and understanding” “Knowledge, understanding and APPLICATION” is

is assessed through a series assessed via a series of COMPETENCE BASED TASKS
of written assignments leading to relating to a specific “key function” eg. installation,
a WRITTEN EXAMINATION. commissioning, fault diagnosis. This is performed on
an INDIVIDUAL basis with the approved assessor.
Success is based upon a minimum of two
performances under different conditions and criteria.

Evidence will include direct observation by the assessor,

questioning and written reports/data.
Success is based upon a satisfactory performance by the
candidate being ASSESSED OBJECTIVELY.

Programmes can be NON-TIME based, or follow a TRADITIONAL EDUCATIONAL SYSTEM.

PRIOR KNOWLEDGE and EXPERIENCE should also be taken into account. Assessment is only
carried out when the candidate is ready and the tutor/assessor is satisfied that sufficient
knowledge and understanding of the subjects have been gained to ensure success.
 15

CETOP QUALIFICATIONS
APPROVED CENTRES GUIDELINE
RELATING TO CETOP OCCUPATIONAL LEVELS
RE 2015/06.02 – H/P

1. INTRODUCTION Before applying for Approved Centre status,

organizations must fully understand that
The purpose of this paper is to provide a specific competence can only be achieved through “real
informative guideline to “Approved Centres” and hands on experience”. It is therefore necessary for
the processes associated with quality assurance centres to have, or have access to, an extensive
and quality control of competence based range of fully operational equipment, which clearly
qualifications. represents present day technology and which is
able to meet the criteria laid down for knowledge
and skills development followed by competence-
2. APPROVED CENTRES based assessment.

If a person is presented with a competence

To ensure candidate performance levels, it is
based qualification, the certificate should clearly
necessary for centres to have technically com-
state:
petent tutors and assessors, with field experience
• The level of competence
in fluid power and associated engineering tech
• The range of skills covered
nologies as well as good academic qualifications.
• The specific area covered by these skills
• The Approved Centre at which the
qualification was obtained To effectively educate, train and carry out
• The name of the controlling organization competence based assessment, staff themselves
(Qualifying Body) and associated signature should, through their own work-based experiences,
of authority. have a range of practical skills involving the
maintenance and management of fluid power
The Approved Centre must be itself assessed systems.
by a representative of the Qualifying Body, to
guarantee that it can effectively and continue- Other important issues are the centre’s ability to:
oily meet the criteria necessary to develop
The knowledge and skills of personnel to a a) Interpret the competence-based programme(s)
level at which they are deemed competent. and effectively integrate the knowledge-based
sections with the development of practical
A major concern is that once a person has skills.
been certified competent he or she “must be”
competent and there must be no doubt placed b) Establish individual candidate “action plans”
upon that person’s capability within the range against prior knowledge and experience.
of skills covered by the certificate.
c) Maintain candidate progress records, providing
Approved Centres are the responsible body for evidence of feedback, evaluation and
ensuring quality and consistency of confidentiality.
performance and should therefore guarantee
these levels of candidate knowledge and d) Establish a series of written assignments to
competence based skills. support the knowledge-based sections.

It is the responsibility of the Qualifying Body e) Establish a series of competence-based tasks

to establish a guideline document clearly explai- to meet the evidence criteria - to be carried
ning to educational establishments and training out on a “one to one” basis or in groups.
organizations their commitment to achieving
and maintaining “Approved Centre Status”. f) Establish a Management Control System,
covering all aspects of document control,
16

including Tutors, Assessors and Internal g) A technical library containing an adequate

Verifiers, involving regular documented supply of current:
management review meetings.
a. Manufacturers’ catalogues and technical
g) Provide quality tuition through an extensive data
range of visual aids, computer-based presen- b. Access to the internet as required to
tations, etc. in lecture rooms conducive to provide current technical data
learning. c. Fluid power Guidelines
d.Training Manuals
h) Provide good library facilities, including where e. Health and Safety Documentation
possible, access to Internet-based information.
Note: All current issue dates should be
recorded and documentation kept at
Further to these requirements, centres must have the current level.
in place, an active Health and Safety and Equal
Opportunities Policy. ISO 9000 or ISO Approval h) Suitable lecture rooms with appropriate
14000 would be seen as most supportive when visual aids to support and present the
the Qualifying Body makes the final consideration programmes. These should include:
for Approved Centre Status. a. Computer-aided presentations
Note: Centres approved at Level 3 are b. Projection Systems
automatically approved for Levels 1 and 2.
On application to the CETOP Member Association
2.1 CETOP Approved Centres’ duties for centre approval using the prescribed form, an
Approved by the CETOP National Associations, approval visit will be arranged. A member appointed
all centres must have in place the following: by the CETOP Member Association will carry out a
site visit on a mutually agreed date to assess the
a) A suitable quality control/management centre, its staff, its equipment base and overall
system to effectively manage the scheme organizational capability to effectively manage and
covering all aspects of registration, induction, deliver the programme/s indicated by the
review and evaluation of individual needs, application. Both parties will agree all arrangements
continuous assessment, performance in writing.
monitoring, final assessment, examinations,
validation and the provision for effective Centres are advised to contact their CETOP
feedback National Association for an outline of all
b) A system for maintaining records in a confi- current costs and for:
dential and secure manner • Centre Approval visit
• CETOP National Association Verification visit
c) Technical/competent staff, with experience • Candidate examination registration
in the field of hydraulic systems, pneumatic
systems and control as applicable to the 2.2 Centre verification
programmes to be delivered and validation of standards

d) Experienced staff to carry out both Approved Centres will be visited by an external
knowledge-based and competence-based verifier (appointed by their CETOP national
assessments to meet the scheme association). The verifier will, in conjunction with
requirements, with reference to the centre, agree upon a date and visit time to
assessment and internal verification suit both parties. Centres will be informed, in
e) An implemented policy covering Health and writing, at least one month before the verifier’s
Safety and Equal Opportunities visit and all procedures, processes and
documentation will be agreed upon prior to the
f) An equipment base to support the tutor in the visit.
presentation of the knowledge-based section,
whilst at the same time providing adequate sup-
port for candidates to practice and develop their The verifier will submit a report to the centre within
skills for the final competence-based 14 days of the visit, plus a copy to the national
assessment (See 2.6 relating to Centre fluid power association. The verifier’s report will
Equipment Provision) include:
 17

a) Acceptance of existing systems and continued transmittal notice “send back” to the CETOP
approval national Member Association on receiving the
pack by registered mail.
b) Recommendations for improvements and
agreed action plan and time scale The CETOP national Member Association will
notify centres of the designated examination
c) Date of next meeting in due time, together with any further details
considered necessary to ensure effective
d) Update on any current changes to the management and control of the examination
programme and approval/verification process.
processes
On completion of the written examination,
candidate’s scripts will be returned to the
2.3 Recommendations examinations officer who will then arrange for
Throughout the programme, both Tutor and
them to be marked by the nominated person
Candidates are expected to use and apply:
against the supplied marking scheme.
a) Hydraulic symbols to current issue level Successful candidates should be reported to
ISO standard the CETOP national Member Association within
one month of the examination date using the
b) Electrical/electronic symbols to current issue prescribed form (Examination Report Form) for
level EN standard knowledge-based units.

Throughout the delivery of the programme, Tutors Note: Centres will receive one extra copy of
will be expected to use a variety of system circuits the examination paper for reference during
to support and reinforce the learning process. invigilation and marking. The Marking
Candidates should be encouraged to use their Scheme provided must be returned to the
own circuitry applicable to the type of machines CETOP national Member Association together
and systems for which they are currently involved with the Examination Report Form.
as part of their employment (where applicable). Under no circumstances must this be copied.
The tutor will in conjunction with individual Where candidates fail to meet the required pass
candidates, review all circuitry and identify its mark and are planning to resit the examination at
suitability. the next available date, the CETOP national
Member Association must be notified by
2.4 Centre programme delivery/methodology completion of the respective Examination Entry
The delivery of these programme/s should include Form.
practical „Hands On“ activities throughout to
reinforce the learning experience. 2.6 Information relating to specific programs

Emphasis must be placed on ensuring Approved Centres must have or have access
candidates receive and achieve a thorough to the following equipment to:
understanding of the core subjects: fundamental
principles, the ability to read and interpret circuit a) provide support for knowledgebased learning
diagrams in symbol form, contamination control
and the application of safe working practices. b) provide for effective tutor demonstrations

2.5 Examination/assessment control procedures c) provide adequate hands on experience during

Examination papers and marking schemes will be skills development and competence-based
prepared by the CETOP national fluid power assessment
association and dispatched to respective centres
or institute. Dispatch will take place by registered 2.6.1 Mobile Hydraulics Programmes
mail at least 2 working days before the designated Centres must have the ability to:
examination date. They will be dispatched to the
designated examinations control officer. 1) Demonstrate cavitation and aeration on the
suction side of pump
He or she will be responsible for the control of
all aspects of confidentiality, administration
and invigilation and in turn the dispatch of the
18

2) Operate a fixed displacement pump system with 10) Investigate the operation of a closed hydro-
a variety of pressure and flow control devices static system incorporating the basic control
covering: functions
• single stage relief valves
•pilot operated relief valves with vent control unloaded 11) Investigate the performance of two-way and
valves three-way pressure reducing valves
•Electro-Hydraulic pressure switches and transducers
•accumulators 12) Demonstrate the procedures to follow to
(including provision for charging) assess the contamination level of hydraulic
Flow control should include simple throttle valves and fluid using a patch test kit
pressure compensated flow control valves, covering
meter-in, meter-out and by-pass operations and 13) Investigate the performance of hydraulic
should be investigated under steering systems and associated priority
load and non-load conditions valves

3) Operate and control a variable displacement pump 14) Investigate hydraulic motor performances
system incorporating: associated with displacement, speed and
• pressure compensation (constant pressure slippage rates
control)
• load sensing 2.6.2 Industrial Hydraulics and Control
• remote pressure control (including the application of Centres must have the ability to:
electrical and proportional control)
1) Demonstrate cavitation and aeration on
4) Show the effects of engine speed and pump the suction side of pump
displacement on pump flow rates
2) Operate a fixed displacement pump system
5) Carry out pump performance testing and with a variety of pressure, flow and
establish the relationship between Q and P under associated control devices covering:
load and non-load conditions • single stage relief valves
• pilot operated relief valves with vent-
6) Investigate the performance of: control
• priority flow control valves • unloaded systems
• spool flow dividers • Electro-Hydraulic pressure switches and
• rotary flow dividers under load and non-load transducers
conditions • accumulators (including provision for
charging)
7) Distinguish the difference between mounted valves, Flow control should include simple throttle
screw-in cartridge, slip-in cartridge and pipe mounted valves and pressure compensated flow control
arrangements, through practical hands on valves, covering meter-in, meter-out and by-
experience pass operations plus the application of flow
divider
8) Operate a variety of multifunction mobile valves and should be investigated under load and
covering: non- load conditions
• open centre applications
• flow/pressure compensation 3) Operate and control a variable
• inlet and service port provisions (including the displacement pump system incorporating:
operation via manual control, oil pilot joystick and • pressure compensation (constant
electrical proportional control) pressure control)
• load sensing
9) Investigate the performance of pilot operated check • remote pressure control (including the
valves and external piloted counterbal- ance valves application of electrical and proportional
for load holding and motion control involving cylinder control)
systems
4) Demonstrate and investigate load holding and
motion control via pilot operated check valves
and over-centre counterbalance valves
 19

5) Incorporate and apply both on-off solenoid 3. EDUCATIONAL ESTABLISHMENTS/

operated valves and proportional control TRAINING ORGANISATIONS

6) Build circuitry involving switches, Before applying for centre approval,

relays and amplifier card systems Educational Establishments/Training
7) Carry out pump performance testing and Organization must be conversant with:
establish the relationship between Q and P
under load and non-load conditions a) The content of the programme for which
they are applying to run.
8) Demonstrate the procedures to follow to
assess the contamination level of hydraulic b) The guideline document outlining the center’s
fluid using a patch test kit specific commitment and requirement to run the
scheme.
9) Investigate the performance of hydraulic
cylinders operating in a regenerative mode Note: The Guideline Document will contain the
necessary forms for application for centre
10) Investigate hydraulic motor performances approval, candidate registration and examination
associated with displacement, speed and entry.
slippage rates

11) Investigate the performance of two-way and 4. QUALIFYING BODY/EXTERNAL VERIFIERS

three-way pressure reducing valves
On receiving the application form for centre
12) Distinguish the difference between mounted approval, the Qualifying Body will arrange a centre
valves, screw-in cartridge, slip- in cartridge visit by one of its elected “External Verifiers”(EV).
and pipe mounted arrangements, through The EV will communicate with the centre and
practical hands-on experience finalise a date and time for the visit. The EV will
notify the centre in writing of all the necessary
2.6.3 Power Pneumatics and Control arrangements for the visit, clearly outlining all areas
Centres must have the ability to: to be checked and discussed as part of the
approval process and the necessary personnel to
1) Build a range of pneumatic circuitry from simple be present.
to complex involving air pilot and solenoid pilot
control
Centres would be advised to forward to the EV,
2) Build Electro-Pneumatic circuits incorporating current copies of CV’s for all personnel involved
relays and a variety of switching devices in the scheme, prior to the visit.

3) Incorporate the application of PLC’s to initiate The EV will normally work from a checklist
control of pneumatic circuitry system and a copy of this can be forwarded to
the respective centre prior to the approval
4) Demonstrate the performance of cylinders with visit (See appendix RE 2015/06.01 - H/P).
and without cushioning
During the visit to the centre the EV will provide:
5) Incorporate into circuitry, safety systems,
interlocks, two hand starts and emergency a) Advice and guidance to the centre, to help
stops them meet the Qualifying Body’s criteria for
centre approval.
6) Investigate the operation of air compressors
and ancillary equipment, receivers, coolers b) Advice and guidance regarding the delivery,
and dryers management and assessment processes
required to effectively run the scheme.
7) Investigate the performance of a variety
and combinations of FRL units On completion of the centre approval visit, the EV
will notify there whether or not they have met the
8) Investigate different pipe-work and sealing necessary criteria to become officially approved.
systems in current use
20

If so, the EV will officially notify the Qualifying Body, b) Review candidate records of achievement.
forwarding all the necessary approval docu- mentation.
The Qualifying Body will then award the centre with its c) Observe competence based practical task
Approved Centre Certificate. assessments, where possible.

Should a centre fail to meet the approval criteria, the EV d) Discuss with Centre Tutors, Assessors and
will discuss a timescale with the centre and the Internal Verifiers, any problems associated with
necessary remedial actions to be taken. the management and daily running of the
scheme.
The Qualifying Body may grant conditional ap-
proval, for a period of up to six months. At this stage, e) Receive from centre staff any objective
full approval will be granted if the centre can present feedback regarding the scheme and
the necessary evidence showing that it has clearly proposed improvements.
met the criteria. This may involve a re-visit by the EV
and this will incur additional costs. f) Provide the centre with any updated information
from the Qualifying Body, which they may not yet
The Qualifying Body will normally approve a have received.
centre for a period of six years, subject to the EV’s
visit and report. Note: It is the responsibility of the
Qualifying Body to have in place a
The EV, on behalf of the Qualifying Body, will be programme for scheme/ qualification review
responsible for developing a close communication link and improvements. This will normally be a
with the centre. It will be the responsibility of the three year process.
Qualifying Body to provide specimen practical The Qualifying Body will notify Approved
competence based tasks, including respective marking Centres in writing through established
schemes, ensuring that Approved Centres adopt a style “Information Updates”. These will include
and content acceptable to the qualification level. recommendations to Approved Centres and
dates for implementation where necessary.
The Qualifying Body will be responsible for setting It will be the responsibility of the Approved
examinations and establishing the necessary Center’s Management Team to meet these
marking schemes, on an agreed time-scale. The requirements.
approved centre will be responsible for the
administration, invigilation, marking and On completion of the centre visit by the EV, a
confidentiality. full report will be submitted to the Qualifying
Body and a copy sent to the respective centre,
Note: Where Qualifying Bodies in Europe do not outlining any agreed improvements, actions or
have the resources to set and administer observations, which need attention. The EV will
examination papers, etc., the alternative is to discuss the outline of his or her report with the
establish an acceptable set of examination papers centre at the end of the visit.
and marking schemes, through the various education
and training establishments, allowing them to
administer and control them accordingly. 6. SUCCESSFUL CANDIDATES
However, the Qualifying Body must agree the
standard, whilst ensuring the content meets the On successful completion of the scheme,
programme and qualifications level. the approved centre will, through the
necessary documented systems, inform the
Qualifying Body of the candidates’ success.
5. EXTERNAL VERIFIER /VERIFICATION VISITS
TO APPROVED CENTRES It will be the responsibility of the Qualifying
Body to award the respective certificate,
During such visits, the EV will: showing the competence base level of
a) Verify the centre against its original centre achievement signed by an authorized
approval documentation, systems and representative of the Qualifying Body.
management control.
 21

APPENDIX: CETOP QUALIFICATIONS

APPROVED CENTRES GUIDELINE
APPENDIX CETOP RE 2015/06.02 - H/P
For example that can be modified by the CETOP Member Associations

Appendices:
Typical Centre Approval Report Forms given for example that
can be modified by the CETOP Member Associations.

CENTRE APPROVAL REPORT FORM

CENTRE APPROVAL APPLICATION (CETOP/CA/1)

CANDIDATE REGISTRATION (CETOP/CR/1)

APPROVED CENTRE: EXAMINATION ENTRY (CETOP/EE/1)

EXTERNAL VERIFIER’S VISIT REPORT (CETOP/EV/1)

INTERNAL VERIFIER’S REPORT (CETOP/IV/1)

WORK EXPERIENCE VERIFICATION (HYDRAULICS EXAMPLE)

22

CENTRE APPROVAL REPORT FORM

1 CENTRE DETAILS 2 RECOMMENDATIONS

Centre Name: Full Approval Tick

Address:

Centre Contact: Conditional Approval

Tel. No. Fax No.

E-mail: Period of Months

External Verifier’s Name:

Date/Time/Visit: Rejection

LEVELS
3 CENTRE APPROVAL SOUGHT FOR CODE
1 2 3
• Hydraulics and Control H

• Industrial Hydraulics and Control IH

• Mobile Hydraulics and Control MH

• Power Pneumatics and Control PP

Please tick the appropriate box.

 23

4 ACCOMMODATION/FACILITIES (Brief Report)

a) Lecture Room Facilities/Layout

b) Visual Aids/Presentation Methods

c) Programme Notes/Support Materials/Software

d) Manufactures Catalogues/CDs/Access to Web Sites/Library

e) Fluidpower Publications and Relevant Standards

Recommendations/Comments
24

5 PRACTICAL FACILITIES/EQUIPMENT AVAILABILITY/ACCESS

At this stage the External Verifier will make reference to “2.6” (pages 17–19) of Guideline Document
relating to the equipment necessary to effectively deliver competence based programmes
Report on the acceptability of the centre’s resources to effectively deliver the programme

Comments

Quality of Equipment

Range of Equipment

Age/Current

Recommendations/Comments
 25

Please tick
CENTRE PROGRAMME DELIVERY AND
6 MANAGEMENT
the appropriate box
YES NO
• Tutor Names: CVs Checked

Comments

• Assessor Names: CVs Checked

Comments

• Internal Verifier: CV Checked

Comments

LEARNING METHODS TO BE USED

Recommendations/Comments
26

Please tick
the appropriate box
7 SCHEME ADMINISTRATION
YES NO
• Candidate Training Plans Established (Format)
Comments

• Candidate Personal Development Plans Established (Format)

Comments

• Systems for Progress Monitoring/Maintaining/Confidential – Secure Records

1. Assignments

2. Practical Task Preparation

3. Practical Task Assessment

4. Written Examinations

RESPONSIBILITY/CONTROLLED BY – (name)

Name of Examinations Officer Met during visit

Tel No.

Fax No.

E-mail

Recommendations/Comments
 27

Please tick the

8 HEALTH AND SAFETY/HYGIENE appropriate box
YES NO
• Health and Safety Policy Operational

• Relevant Safety Notices in place

• Risk Assessment carried out and recorded

Recommendations/Comments

9 EQUAL OPPORTUNITIES POLICY IMPLEMENTED

Comments

10 EXTERNAL VERIFIER‘S SUMMARY/RECOMMENDATIONS

EVs Signature Date

Technical Manager National Fluid power Association Date

28

CETOP APPLICATION FOR CENTRE APPROVAL

Form CETOP/CA/1 Copy form as required

Send Back to national CETOP Member Association

Programme for Approval (name)

Name of Organization Full

Address Contact Name

Tel No Position

Fax No

E-mail Web

I have thoroughly read the CETOP Guideline Documents & Recommendations and I am fully aware of
the necessary organizational commitment and equipment base required for Centre Approval.

I am aware of the associated costs for centre visits and would like you to arrange a visit to our
organization to carry out a Centre Approval investigation.

We will forward to the national CETOP Member tick as applicable

Association: Payment via Purchase order [ ]
[ ]

Date Signed

For official use by CETOP Member Association staff

Date Application Received

Actioned by

Name of ET Member carrying out Centre Approval

Visit Date Planned

Outcome of visit

Financial Transactions completed

Date completed

Any other info:

 29

CETOP INDUSTRY STANDARD QUALIFICATIONS

Candidate Registration
Form CETOP/CR/1 Copy form as required

This form must be completed by the Candidate and Approved Centre and returned to the National
CETOP Member Association within 14 days of the date on which candidates are initially enrolled on
to the prescribed CETOP programme.
The Centre will receive a Registration No. for each candidate from the CETOP Member Association,
and all correspondence associated with the candidate should include this number. Once registered,
this number is for life.

Personal Details (To be completed by the Candidate - BLOCK CAPITALS)

Full Name

Position

Employer’s Name

Employer’s Address

Contact Address (Home)

Tel No Date of Birth

Fax No E-mail

.......…………………………………………………………………………………………………
Programme Details
(To be completed by the Approved Centre - BLOCK CAPITALS)

Centre

Programme

Date of Enrolment

Signed Date

CETOP M. A. REGISTRATION NUMBER :

.…………………………………………………………………………………………......………
Internal Record
(For Centre use)

Examination (written)

Practical Task Assessments

30

CETOP APPROVED CENTRE: Examination Entry

Form CETOP/EE/1 Copy form as required

This form must be completed by the Approved Centre and returned to the CETOP M. A. at least 2
months before the examination date. Centres will be charged based upon the number of candidates
recorded and examination scripts will be sent to the centre accordingly.

Prescribed Programme/Scheme
Written Examination Date

Name of Organization

Full Address

Contact Name Position

Tel No Fax No

E-mail Web

Signature Date

The listed candidates will be sitting the written examination on the above date.

NOTE: This same form will also be used to record PASS or FAIL. From this information CETOP M.
A. will send the respective Candidates’ Qualification Certificates to the Approved Centres for dispatch.
No Candidates Name CETOP M. A. Examination Competence- CETOP M. A.
Registration No. Results based-Units official use:
P= Passed P= Passed Certificate
F= Fail Dispatched/Date

10

11

12
 31

CETOP EXTERNAL VERIFIER’S VISIT REPORT

Form CETOP/EV/1 Copy form as required

External Verifier’s Date:

Name: Approved Schemes

Centre: Approved:

Centre Contact Person/IV: Approval:

STANDARDS – (Tick a necessary)

AUDIT CHECKS CARRIED OUT UNSATISFACTORY MEETING SCHEME
REQUIREMENT
1 Overall Management
Including:
• Scheme Management Candidate
• Systems for Tracking Progress
• Areas of Responsibility
• Document Control System
• Health and Safety Policy
• Quality Systems
• Internal Verifier Reports
2 Individual Candidate Records
(Random Check)
3 Inspection of Candidate Assignments
4 Inspection of Practical Task Assessments
5 Inspection of Candidate Individual Portfolios
6 Inspection of Completed Examination
Scripts

ANY ADDITIONAL CHECKS CARRIED OUT

External Verifier’s Comments:

Actions to be taken:

Tick
Copy Sent to Approved Centre [ ] Date:

Copy Sent to CETOP M. A. [ ] Date:

Copy to File [ ] Date:

32

CETOP INTERNAL VERIFIER’S REPORT

Form CETOP/IV/1 Copy form as required

Internal Verifier’s Name:

Approved Centre:

Qualifications Under Review:

Candidate Start Date:

Date of Verification: Report No:

Initial Information Required

(Answer or Tick Box)

1 Number of candidates enrolled and registered with CETOP M. A.:

2 Number of candidates active on scheme to date:

3 Number of candidates taking next written examination:

4 Number of candidates successfully completed written examination:

5 Number of candidates preparing to resit examinations:

6 Number of candidates completed/part completed practical task:

Verification
(Organizational and Quality Control)
CHECKED
Yes No
I Candidate individual record folders – content against checklist [ ] [ ]

II Candidate assignment progress records [ ] [ ]

III Register for candidates attending modules [ ] [ ]

IV Course feedback reports from candidates (4 monthly) [ ] [ ]

V Completed practical task assessment profiles [ ] [ ]

Please tick the appropriate box.

 33

Verification
(Assessment Process)
Yes No

Discussed candidate progress with assessor/s [ ] [ ]

Please tick the appropriate box.

Assessor/s Name/s:

Comments:

Final Remarks
Overall performance of Centre to meet the scheme requirements as laid down by the
national CETOP Member Association and meeting requirements of the External Verifier.

………………………………………………….. Acting as Internal Verifier on behalf of this Centre I am

Satisfied/Not Satisfied with the scheme management, records and methodology.

Actions/Recommendations:

Tick

Copy Sent to External Verifier [ ] Date:

Copy to File [ ] Date:

 34

WORK EXPERIENCE VERIFICATION

Candidate Registration
Form CETOP/WE/1 Copy form as required

This form must be completed by the Candidate and the employer and returned to the National Fluid
power Association (CETOP M.A.).

Personal Details (To be completed by the Candidate - BLOCK CAPITALS)

Full Name

Position

Employer’s Name

Employer’s Address

Contact Address (Home)

Tel No Date of Birth (Civil reg. no.)

Fax No E-mail

.......…………………………………………………………………………………………………

EMPLOYER WORK EXPERIENCE: Verification Entry

Form CETOP/VE/1 Copy form as required

This form must be completed by the Employer of the candidate and returned to the CETOP M. A. by the
candidate.

Employer Programme/Scheme
Personal Details (To be completed by the Employer representative - BLOCK CAPITALS)

Verification Date

Name of Organization Full

Address

Contact Name Position

Tel No Fax No

E-mail Web

Signature Date
 35

Practical task assessments to verify competency about:

• INSTALLATION
• COMMISSIONING

• PERFORMANCE TESTING
• PROACTIVE MAINTENANCE AND MACHINE MANAGEMENT
• SERVICING
• COMPONENT REMOVAL AND REPLACEMENT
 36

Verified by employer, system related, work based

experience
Instruction:
Describe what type of work the candidates have been done within:

 INSTALLATION
Describe experience in reading hydraulic diagram for assembly

Describe experience of assembly based on cleanliness, security and quality.

 37

 COMMISSIONING and PERFORMANCE TESTING

Describe experience of commissioning in respect by person, component, system security and
cleanliness.

Describe experience of system functional testing

 38

 PREDICTIVE MAINTENANCE AND MACHINE

MAINTENANCE PLUS SERVICE
Describe experience of predictive maintenance

Describe experience of fault finding and repair (dis-assembly and assembly of existing system)
 39

Appendix 1. Certification of practical experience

If experienced,
1: Control and adjustment: tick with an X
Flow
Speed on certain movements
Temperature
Accumulator pressure/pre-charge pressure
Fluid cleanliness according to ISO classification system
Sensors and switches for fluid system

2: Fault finding in systems:

From diagram and symptom
With test equipment
Without test equipment. Feel, smell, listen
By phone description

3: Understand security and environmental issues at dis-

assembly of complete or part of fluid systems and machines:
Read and understand maintenance and security instructions
What means by Lockout and Tag out instructions
Secure movements with plunge or similar equipment
Check and dis-charge trapped pressure within pipes
Dis-charge accumulators

Without maintenance and safety instructions, from diagram and machine

structure, analyze actions to be done to be able to work safe
Cleanliness at dis-assembly of system.

Understand the importance of managing waste fluids in a safe manner due to

environmental issues
Understand the importance of using relevant personal protection

4: Maintain and repair fluid power systems:

Maintaining systems:
Exchange sealing’s
Check mounting surfaces
Couplings
Flanges
Valves
Empty and refill fluid in systems
Inside cleaning
Cleaning coolers
Exchange filter cartridges
Exchange components:
Pumps
Valves
40

Fluid motors
Electric motors
Accumulator piston and bladder
Cylinders
Hoses
Other components

Repair of components, dis-assemble, analyze status, exchange wear

parts and re-mount:
Pumps
Motors
Valves
Cylinders
Accumulators

5: Start-up of fluid power systems after maintenance work / exchange of

component:
Flushing
De-aeration
Adjust pressure and flow
Leakage control
Control of cleanliness level according to ISO code system
Cleaning of workplace
Documentation

For approved practical experience shall the candidate have practical experience of at least 50%
of above listed.

Comments about experiences.

EDUCATION
RECOMMENDATIONS

HYDRAULICS PROGRAMMES

POWER HYDRAULICS PROGRAMME (H1): RE 2015/06.01 – H

CETOP (Passport) Occupational Level 1

HYDRAULICS &
ASSOCIATED CONTROL PROGRAMME (H2): RE 2015/06.01 – H
CETOP (Passport) Occupational Level 2

MOBILE HYDRAULICS &

ASSOCIATED CONTROL PROGRAMME (MH2): RE 2015/06.01 – H
CETOP (Passport) Occupational Level 2

INDUSTRIAL HYDRAULICS &

ASSOCIATED CONTROL PROGRAMME (IH2): RE 2015/06.01 – H
CETOP (Passport) Occupational Level 2

HYDRAULICS &
ASSOCIATED CONTROL PROGRAMME (H3): RE 2015/06.01 – H
CETOP (Passport) Occupational Level 3

MOBILE HYDRAULICS &

ASSOCIATED CONTROL PROGRAMME (MH3): RE 2015/06.01 – H
CETOP (Passport) Occupational Level 3

INDUSTRIAL HYDRAULICS &

ASSOCIATED CONTROL PROGRAMME (IH3): RE 2015/06.01 – H
CETOP (Passport) Occupational Level
No part of this publication may be photocopied or otherwise reproduced without the prior permission in writ-
ing of the Association. Whilst the Association does its best to ensure that any information that it may give is
accurate, no liability or responsibility of any kind is accepted in this respect by the Association, its members,
its servants or agents.
42

FOREWORD

These Competence Based Qualifications have The level 3 programmes place emphasis on
been developed by CETOP to meet the occu- complex systems, integrated operations and their
pational levels of those people involved in the associated controls including the electrical /
maintenance and management of fluid power electronic interface. They involve technical speci-
systems and cover the specific subjects of mobile fications and the development of greater in-depth
hydraulics, industrial hydraulics, power pneu- know ledge associated with component character-
matics and associated control systems. They form istics, system performance and interpretation.
a structure for progressive learning and the Each level involves calculations and the use of
acquisition of a range of competence assessed formulae, emphasis is also placed upon the ability
skills. They have now been accepted by CETOP to read and interpret circuit diagrams. The
as industry standard qualifications forming part development of diagnostic skills and the ability to
the harmonization programme and the proposed act accordingly is involved at every level thereby
passport for Europe within this sector of applying a fault-cause-remedy approach through-
engineering. out.

Relating to CETOP Occupational Levels Where the same subjects appear at more
than one level they are dealt with at the
appropriate depth and in a manner that meets
Level 3
the requirements of that level.
Hydraulics (H3)
Mobile Hydraulics (MH3) It is advisable in all cases to study the
Industrial Hydraulics (IH3)
content of the previous levels before taking a
higher level. This will ensure that your prior
Level 2
theoretical know ledge and application
Hydraulics (H2) experience is sufficient for you to proceed.
Mobile Hydraulics (MH2) You should seek advice from your nearest
Industrial Hydraulics (IH2)
Approved Centre and if in doubt arrange a
formal meeting with a tutor to carryout an
Level 1
analysis to identify your strengths and weak-
Hydraulics (H1) ness and jointly establish a plan for your pro-
gression.
For further details of these industry standard
qualifications and Approved Centres visit the
web-site: www.cetop.org.

Developed on behalf of the CETOP Education

Each level can be considered as a stand-alone Commission, representatives from CETOP
qualification and level of achievement. However, member associations, this programme
each level progresses to a higher level of know- represents one of a range of new competence
ledge, understanding and application. based qualifications recommended by CETOP.
In all cases candidates should ensure that they It is intended for those personnel involved in the
have the appropriate knowledge and experience maintenance and management of hydraulic
to commence the qualification level chosen. Level systems used in mobile applications and who
1 programmes provide a foundation of knowledge require knowledge and competence based skills
with emphasis placed upon fundamental to support work based activities such as:
principles, component functionality, operation and planning and preparation, interpreting and using
recognition together with an understanding of fluid technical information, devising and following
power systems at a basic level. sound procedures associated with installation,
The level 2 programmes ensure component commissioning, testing, fault diagnosis,
functionality, operation and application are fully rectification, maintenance, servicing and re-
understood. These programmes have a higher establishing a machine "fit for purpose".
technical content than the level 1 programmes
and provide a more in-depth approach to function,
operation, application and the interpretation of
circuitry.
 43

HYDRAULICS PROGRAMME (H1):

RE 2015/06.01 – H
CETOP (Passport) Occupational Level 1
INTRODUCTION • PROACTIVE MAINTENANCE AND MACHINE
MANAGEMENT
This is the LEVEL 1 Hydraulics Programme, • SERVICING
forming the start of a series of competence- • COMPONENT REMOVAL AND
based qualifications designed around CETOP REPLACEMENT
occupational levels.
The development of planning and preparatory
It combines the necessary knowledge and skills, the use of technical information and
competence based skills for those people on specifications and the formulation and
route to a higher level qualification at levels 2 and implementation of safe working procedures will
3, involving the maintenance and management of be emphasized throughout all aspects of this
both Industrial and Mobile hydraulic systems. programme.

Note: In all cases, each programme METHODOLOGY AND ASSESSMENT

represents a ”stand-alone” qualification but
can also be a progressive route to a higher The programme can be offered via a range of
level. learning modes devised by the Approved
Centres ranging from that of short courses to
CETOP OCCUPATIONAL LEVEL 1 distance learning and centre based modules.
The time scale can also be flexibly managed by
LEVEL (1) This person will perform activities that the Approved Centres.
follow an established procedure. Activities will be
recurring and of a short-term nature. The reaction Candidates will be expected to complete a series
to most problems will be to summon help or of written assignments throughout the
follow a predefined set of actions. programme of study to reinforce the learning
process. These can be supportive to the final
This level 1 programme provides an excellent marks for the knowledgebased section.
introduction to power hydraulics and places great • Final assessment for the knowledge--
emphasis on the understanding of fundamental based units will be by means of a written
principles, component functionality and examination of 2 hours duration. These
principles of operation. will be prepared and offered at approved
centres or at an engaged external
Emphasis upon health and safety and that of examination centre. The pass mark for
developing safe working practices is applied the written examination will be 60%.
throughout, as a CORE ELEMENT within the
scheme. CORE ELEMENTS are not • Practical task competence based unit assess-
necessarily taught as specific subject areas ment will be carried out on a ”one to one” basis
but integrated within the scheme. or in groups, candidate to tutor, on a pass/fail
basis, against agreed evidence of performance.
Throughout the programme, emphasis is placed
upon the development of knowledge relating No part of this publication may be photocopied or
to ”FUNCTION”, ”OPERATION” and ”APPLI- otherwise reproduced without the prior
CATION”. The knowledge based section will permission in writing of the Association.
support the development and effective
application of practical skills necessary to carry Whilst the Association does its best to ensure
out in a safe and effective manner: that any information it may give is accurate, no
liability or responsibility of any kind is accepted in
• INSTALLATION this respect by the Association, its members, its
• COMMISSIONING servants or agents.
• PERFORMANCE TESTING

No part of this publication may be photocopied or otherwise reproduced without the prior permission in writing of the Association.
Whilst the Association does its best to ensure that any information that it may give is accurate, no liability or responsibility of any kind is accepted in this respect by the Association,
its members, its servants or agents. Further copies of this document can be obtained from the CETOP, e-mail: [email protected]. PDF-version of this document can be
obtained from the CETOP web-site: www.cetop.org.
44

PRACTICAL TASK ASSESSMENT (H1) H1.2.3 Correct range of pressure gauges and
connections used at all times.
When assessing competence, the H1.2.4 Pressure readings taken and
following processes must be followed: recorded.
• Relating to the occupational level, a series of H1.2.5 Safe working practices followed at all times.
Assessed Abilities are identified. These H1.2.6 Written report completed covering all
represent the ”DOING PART” of a person’s findings.
job and requires a combination of both
practical skills and applied knowledge. Assessed Ability
• For each Assessed Ability, evidence of H1.3 Change filter element on a system.
performance is then established and
shown as EVIDENCE REQUIRED Evidence Required
(sometimes termed performance criteria). H1.3.1 Risk assessment check carried out and
working procedures established.
In all cases candidates must meet the H1.3.2 Specification of new element (element
requirements of each Assessed Ability. checked against machine specification part
number type and size).
During practical task assessment, the H1.3.3 Correct isolation procedures followed before
ASSESSOR will agree the ”type of evidence” dismantling process commenced.
to be obtained and this can range from: H1.3.4 Correct tools used at all times.
• Direct Observation H1.3.5 Cleanliness control procedures followed and
• Verbal Questioning/Candidate Commentary spillage of oil prevented at all times.
• Written Report H1.3.6 Filter disposal procedures established.
and may include all types. H1.3.7 Operational checks carried out after
installation (system ”fit for purpose”).

ASSESSMENT REQUIREMENTS Assessed Ability

H1.4 Check accumulator pre-charge pressure and
Assessed Ability establish level against specification.
H1.1 Recognize the component parts of a
selected machine and their functionality, Evidence Required
linked to system and circuit diagram. H1.4.1 Established procedures followed at all times.
Evidence Required H1.4.2 Safe working practices followed at all
H1.1.1 Reservoir and associated parts identified times.
including functionality. H1.4.3 Correct tools and test equipment used.
H1.1.2 Pump type identified and associated H1.4.4 Written report completed covering all actions
connections. taken.
H1.1.3 Method used for controlling pressure
identified.
H1.1.4 Method used for controlling flow KNOWLEDGE BASED UNIT (H1)
identified. H1.1.5 Actuator type identified.
H1.1.6 Filter location identified and associated filter H1.5 Contents
performance indicator. H1.5.1 Fundamental Principles.
H1.5.2 Hydraulic System Construction (BASIC
Assessed Ability BUILDING BLOCKS).
H1.2 From circuit diagram provided and associated H1.5.3 Components – Function and Operation.
system, check operating pressures at H1.5.4 Hydraulic Fluids.
strategic points and record. H1.5.5 Cleanliness Control.
H1.5.6 First Line Management.
Evidence Required H1.5.7 Maintenance Procedures.
H1.2.1 Safety checks carried out before pressure
checks commence and working environment
assessed.
H1.2.2 Test points identified on circuit diagram and
machine system, check list established.
 45

Health and Safety CORE ELEMENT

• flow rate, displacement and motor speed
• Do’s and Don’ts • pump displacement, shaft speed and flow rate
• Good/Safe Working • pump flow rate, operating pressure and
Practices/Risk hydraulic power volumetric efficiency,
Assessments mechanical efficiency and overall efficiency of
pumps and motors
Literacy • pipe diameters, flow rates, fluid viscosity and
and Numeracy pressure losses
CORE ELEMENT
• Use of Basic Formula c) Know the units and terminology relating to:
• Application of Simple • flow rate
Calculations and
• speed
Associated Units
• pressure
• Terminology • temperature
• power
KNOWLEDGE BASED UNIT – • torque
WRITTEN EXAMINATION SPECIFICATION • motor and pump sizes

The examination paper will contain questions H1.5.2 Hydraulic System Construction and
from the 7 sections of this programme and core Symbolic Representation
elements will be integrated as necessary. a) Know the component parts used to
• Examination minimum duration 2 consecutive construct a hydraulic system and the
hours basic layout (basic building blocks).
• Pass mark 60%
• Question style may be single subject, multiple b) Outline the function of the component parts
subject, short answer and multiple choice used to design a hydraulic system relating to:
• prime mover
Where calculations and formulae are involved, all • coupling and bell housing
progressive stages of the calculation together with • pumps
their corresponding units must be shown. • reservoir
• filters
HYDRAULICS - (Knowledge Based Unit) • pipes – rigid and flexible
• relief valves
H1.5.1 Fundamental Hydraulic Principles • pressure reducing valves
a) Know the fundamental principles that underpin the • direction control valves
operation of all hydraulic systems and how they • flow control valves
affect performance: • hydraulic motors
• flow makes it go • hydraulic cylinders
• pressure provides the pushing force • pressure gauges
• oil in a system always takes the path of least • flow meter
resistance • check valves- inline and pilot operated
• pressure is a measure of the resistance to flow • bladder accumulator
• for oil to flow in any system, there has to be a
pressure difference c) Recognize and use current graphical
• the greater the pressure drop the greater the hydraulic symbols to represent the
flow potential component parts of a hydraulic system.
• when fluid flows from a high pressure level to (ISO standards).
a lower pressure level and no work is carried out,
then heat is generated H1.5.3 Operation of the Major
Components used to design a
b) State and use the relationship between: Hydraulic System
• pressure, area and the force transmitted by a Describe the operating principles of the
cylinder following components:
• flow rate, cylinder dimensions and piston velocity
• pressure, displacement and hydraulic motor • gear pump (external)
torque • vane pump (cartridge type)
46

• piston pump (swash plate – pressure H1.5.6 First Line Management of

compen- sated) Hydraulic Systems
• relief valve (direct and pilot operated) a) Know the points of inspection and the observa-
• pressure reducing valve tions to be made:
• direction control valves (lever • Power unit and prime mover:
operated and solenoid operated) • Stop – Start – Isolation
• pilot operated check valve • general external cleanliness
• throttle valve (with and without free flow • position and security of all guards
check valve) •relevance of all notices – risk assessment
• pressure compensated flow control valve noise level and general temperature hydraulic
• filter with bypass and differential indicator oil level and color at sight glass
• hydraulic motor (piston and orbit) •suction hose connections and
• cylinders (tie rod and screwed body types) hose conditions
• cylinder cushioning • pressure gauge readings
• accumulator and safety block • signs of leakage
• security of fittings – pipes and hoses
H1.5.4 Hydraulic Fluids and their • filter indicator status
Characteristics •reservoir access points and
a) Know the meaning of the following terms: sealing arrangements
• viscosity •accumulator inspection and
• ISO viscosity grade associated safety block
• viscosity index (pre-charge pressure checks)
•general structure of power unit
b) Know the function of the hydraulic fluid: (steel work)
• power transmission • Hydraulic System:
• lubrication • operation of services
• cooling (feedback from operator)
• carrying contaminants to the nearest filter • leakage (cylinders, motors, hoses,
sub-plates and stacks) view topping up record
c) Outline the effect of system temperature on: • pressure readings inline with operating speci-
• oil viscosity and system performance fication
• noise and vibration
d) Know the factors that affect the life of the • system filter and indicator status
hydraulic fluid and their effect upon system
performance: b) Know how to effectively complete a written
• contamination report covering:
• heat • non compliances
• moisture • actions taken
• request for further investigation
H1.5.5 Contamination Control
a) Know the origin of contamination and ways in H1.5.7 Maintenance Procedures
which it enters a system. a) Know the requirements of a pro-active mainte-
nance programme with reference to health
b) Outline procedures to follow to reduce and performance monitoring and relating to:
contamination ingression. • pump performance testing (QP)
• periodically taking pressure readings under
c) Know the effects of contaminants on the life and vary- ing operational conditions
performance of component parts. • taking regular oil samples to enable
cleanliness level to be assessed
d) Know the locations of filters within a system. • taking regular oil samples to determine oil
life expectancy
e) Outline the performance of a filter, • checking systems temperatures
including by-pass and indicator. • checking working performance (time based
op- erations)
f) Know the importance of regular fluid contami- nation b) Know how to effectively complete a written
analysis and the correct interpretation of the results. report covering:
• non compliances
• results identified
• actions taken
• request for further investigation
 47

HYDRAULICS & ASSOCIATED CONTROL PROGRAMME

(H2) CETOP RE 2015/06.01 - H
CETOP (Passport) Occupational Level 2

INTRODUCTION

This is a LEVEL 2 Hydraulics Programme, of safe working procedures will be emphasized

forming the start of a series of competency- throughout all aspects of this programme.
based qualifications designed around CETOP
occupational levels. METHODOLOGY AND ASSESSMENT

It combines the necessary knowledge and The programme can be offered via a range of
competency based skills for those people on learning modes devised by the Approved
route to a higher level qualification at level 3, Centres ranging from that of short courses to
involving the maintenance and management of distance learning and centre based modules.
hydraulic systems. The time scale can also be flexibly managed
by the Approved Centres.
Note: In all cases, each programme represents
a ”stand-alone” qualification but can also be a Candidates will be expected to complete a se-
progressive route to a higher level. ries of assignments throughout the programme of
study to reinforce the learning process and attend
CETOP OCCUPATIONAL LEVEL 2 the programme of centre based modules.

LEVEL (2) This person will perform a variety of Final assessment for the knowledge-- based units
activities needing some understanding of the will be by means of a written examination of 2
technical factors involved. The activities may re- hours duration. These will be prepared and offered
quire the interpretation and application of varied at approved centres or at an engaged external
and non-routine specifications. Activities will examination centre. The pass mark for the written
involve the use of simple diagnostic checks and examination will be 60%.
ability to make a positive response to deviations.
Co-operation with others in team or work groups The expected completion time for this competency
may be required. based programme is 1-2 years but this does depend
upon previous experience and the learning mode
Throughout the programme, emphasis is placed devised by the centre and will require a high level
upon the development of knowledge relating to of personal commitment to study and research the
”FUNCTION”, ”OPERATION” and ”APPLICA- subjects within the syllabus.
TION”. The knowledge based section will support
the development and effective application of Practical task preparation and competency-based
practical skills necessary to carry out in a safe and unit assessment will be carried out by arrange-
effective manner: ment with the approved centre during the year.
Final assessment will be carried out on a ”one to
• INSTALLATION one” basis or in groups, candidate to tutor, and the
• COMMISSIONING outcome will be pass or fail.
• PERFORMANCE TESTING
• PROACTIVE MAINTENANCE AND MACHINE Successful completion of both the knowledge-
MANAGEMENT based and competency-based units will result in
• SERVICING the award of a CETOP Level 2 Hydraulics
• COMPONENT REMOVAL AND REPLACEMENT Qualification Certificate. (Candidates successfully
completing only one unit might receive a CETOP
The development of planning and preparatory Unit Certificate).
skills, the use of technical information and speci-
fications and the formulation and implementation No part of this publication may be photocopied or
otherwise reproduced without the prior permission
in writing of the Association.

No part of this publication may be photocopied or otherwise reproduced without the prior permission in writing of the Association.
Whilst the Association does its best to ensure that any information that it may give is accurate, no liability or responsibility of any kind is accepted in this respect by the Association,
its members, its servants or agents. Further copies of this document can be obtained from the CETOP, e-mail: [email protected]. PDF-version of this document can be obtained
from the CETOP web-site: www.cetop.org.
 48

Whilst the Association does its best to ensure Assessed Ability

that any information it may give is accurate, no H 2.2 Assemble a hydraulic system from given
liability or responsibility of any kind is accepted information and carry out effective fault
in this respect by the Association, its members, diagnosis.
its servants or agents.
Evidence Required
PDF version of this document can be obtained H 2.2.1 Components selected and checked
on the CETOP web-site: www.cetop.org against specification.
e-mail: [email protected] H 2.2.2 Installation plan prepared
(order of actions to be taken).
H 2.2.3 Safe working practices followed
PRACTICAL TASK ASSESSMENT at all times.
H 2.2.4 Components commissioned by following
When assessing competency based skills,
prescribed procedures.
the following processes must be followed:
H 2.2.5 Start-up procedures followed.
H 2.2.6 System operational checks carried out
• Relating to the occupational level, a series of
and results recorded.
Assessed Abilities are identified. These repre-
H 2.2.7 System operates according to
sent the ”DOING PART” of a person’s job and
specification.
requires a combination of both practical skills
H 2.2.8 System fails to operate according to
and applied knowledge.
specification – ”Fault, Cause, Remedy”
• For each Assessed Ability, evidence of
Approach to fault diagnosis is
performance is then established and shown
effectively applied to re-establish
as EVIDENCE REQUIRED (sometimes
termed performance criteria).
Assessed Ability
H 2.3 Pump performance test carried out to assess
In all cases, candidates must meet the require- Q/P relationship under load conditions.
ments of each Assessed Ability on at least two
occasions. Evidence Required
H 2.3.1 Correct diagnostic equipment selected.
During practical task assessment, the
H 2.3.2 Establish test procedures followed.
ASSESSOR will agree the ”type of evidence” to
H2.3.3 Safe working practices followed at all times.
be obtained and this can range from:
H2.3.4 Pump specification checked.
H 2.3.5 Performance results recorded and written
• Direct Observation report completed covering all actions taken.
• Verbal Questioning/Candidate Commentary
• Written Report
Assessed Ability
and may include all types.
H 2.4 System contamination levels assessed against
established target cleanliness levels.
Assessment Requirements
In practical tasks, candidates must on at least
Evidence Required
two occasions, prove their ability to carry out
H2.4.1 Established oil sampling procedures followed.
the following:
H2.4.2 Cleanliness control procedures followed to ensure
representative sample is taken.
Assessed Ability
H2.4.3 Sample identification procedures followed.
H 2.1 Interpret hydraulic circuit
H2.4.4 Safe working practices followed at all times.
diagrams applicable to
H2.4.5 Sample analysis procedures followed and
selected systems.
comparison checks made to determine cleanliness
level.
Evidence Required
H2.4.6 Written report completed.
H 2.1.1 Machine function and operation
correctly identified.
H 2.1.2 Components named and
function identified.
H2.1.3 Component control methods identified.
 49

HYDRAULICS PROGRAMME KNOWLEDGE

BASED UNIT c) State and use the relationship between:
• pressure, area and the force transmitted by
CONTENTS a cylinder
• flow rate, cylinder
H2.5.1 Fundamental Hydraulic Principles. H2.5.2 dimensions and cylinder
Hydraulic System Components. velocity
H2.5.3 Pumps and Associated Control Systems. • pressure, displacement and hydraulic
H2.5.4 Hydraulic Actuators. motor torque
H2.5.5 Circuitry and Control Features. H2.5.6 • flow rate, displacement and motor speed
Hydraulic Fluids. • pump displacement, shaft speed and flow rate
H2.5.7 Reservoirs and Conditioning Equipment. • pump flow rate, operating
pressure and hydraulic power
• volumetric efficiency, mechanical efficiency
• motors and actuators
and overall efficiency of pumps and motors
• filters and coolers
• pipe diameters, flow rates, fluid
• pipe work, rigid and flexible
viscosity and pressure losses
H 2.5.2 Hydraulic System Components
d) Outline the basic building blocks and
Describe the function and operation of control
circuit configuration for a typical machine:
valves and recognize their graphical symbols on
• electric motor/engine
associated circuitry.
• main and auxiliary pumps
• reservoir and fluid
a) Flow control:
• steering and braking systems
• flow control devices both fixed and adjustable
H2.5.8 Hydraulic pressure equipment and safety
• pressure and temperature compensated
components • valve control systems
flow control devices
H2.5.9 Contamination Control.
• flow dividers – spool, rotary and priority
H2.5.10 Maintenance, Monitoring and Fault Finding.
b) Pressure control:
KNOWLEDGE BASED UNIT –
• relief valves – single and two stage
WRITTEN EXAMINATION
• vented vent control and unloading principles
SPECIFICATION
The examination paper will contain questions from
• pressure reducing – single and two
all sections of the programme.
stage (two way and three way
operations)
• Examination minimum duration 2 consecutive hours
• counterbalance with remote pilot
• Pass mark 60%
• joystick control
• Question style may be single subject, multiple
• sequence valves
subject, short answer, multiple choice
• All questions will carry equal marks c) Load Holding and Motion Control:
• pilot operated check valves
Where calculations and formulae are involved, all
• counterbalance with remote pilot
stages of the calculation together with their corre-
• hose burst valves
sponding units must be shown.
d) Directional Control devices
HYDRAULICS PROGRAMME - and methods of control:
(Knowledge Based Unit) • check valves
• pilot operated check valves
H 2.5.1 Fundamental Hydraulic Principles • spool valves – including two stage
State and use the fundamental principles • multiple port mobile valve (open and closed
underpinning the operation of Hydraulic systems center including load sensing arrangements,
and know how they affect performance: involving pre-compensation)
• control methods including manual, oil pilot
a) Pascal’s Law (static and dynamic pressure). and Electro-Hydraulic
• poppet valves
b) Know the cause and effect of pressure gen-
• rotary valves
eration, pressure losses, heat generation, fluid
leakage, cavitation, aeration, noise and vibration. • manual/pilot/on-off solenoid operation
• introduction to proportional control
50

H 2.5.3 Pumps and Associated Control

Systems Describe the function and operation of d) Semi-rotary actuators:
Hydraulic pumps and listed control systems, plus • rack and pinion type
set up pro- cedures as prescribed. • vane type
• others
a) Pumps: H 2.5.5 Circuitry and Control Features
• external gear Interpret listed circuitry, including basic
• internal gear electrical symbols and circuits.
• gerotor a) counterbalance and load holding
• vane (fixed and variable)
• axial piston (fixed and variable) b) closed hydrostatic circuitry including:
• bent axis (fixed and variable) • pump control features
• radial piston (fixed and variable) • motor control features

b) Control features: c) two pump unloaded valve circuit

• fixed pumps with relief valve involving vent
control d) pump control circuit including pressure
• unloading (two pump system) compensation, load sensing and constant
• pressure compensation with and without load pow- er/torque
sensing
• manual displacement control e) hydrostatic steering circuitry (non-dynamic)
• constant power control including:
• open center
c) Pump relationship between pressure and flow • closed center
(Q/P) characteristics.
f) mobile valve circuitry involving joystick pilot
d) Compensator setting up procedures involving oil control, including:
standby and pressure limiting compensators. • open center valve spool arrangements
• closed center valve spool arrangements
e) Effects of electric motor/engine speed on pump
performance. g) braking circuitry involving:
• parking brakes
H 2.5.4 Hydraulic Actuators • service brakes
Describe function and operation of hydraulic
actuators. h) regenerative circuitry
a) Motor types:
• gear i) power take off arrangements for pump
• gerotor/orbit trans- mission applying step up/step down
• vane gearbox
• radial piston – single and two speed
• axial piston – fixed and variable displacement j)Electrical symbols and associated circuitry:
• bent axis – fixed and variable displacement • NO and NC contacts
• solenoids (AC and DC)
b) Motor performance: • relays
• series circuitry
• parallel circuitry H 2.5.6 Hydraulic Fluids
Describe the functions and characteristics of
c) Cylinders, types, construction, sealing and hydraulic fluids.
mounting arrangements:
• single acting a) Functions:
• double acting • power transmission
• through rod • lubrication
• sealing • cooling
• mounting arrangements • sealing
• cushioning • carrier for contaminants
 51

b) Characteristics and properties and their H 2.5.9 Contamination Control

effect on system performance: Describe contamination control methods.
• viscosity
• viscosity index • origins of contamination
• lubricity • cleanliness targets – achieving and maintaining
• oxidation • monitoring fluid condition (sampling and
• pour point measurement)
• demulsibility • preventive/correction actions
• material compatibility • filter performance and ratings
c) Oil types and application: • filter types
• mineral oil • locations and performance
• emulsions
• glycols H 2.5.10 Maintenance, Monitoring and Fault
• bio-degradable fluids Finding Procedures
• engine oils (SAE grades) Describe maintenance, Monitoring
• transmission fluids and fault finding procedures.

d) Storage, handling and transfer: a) Know the importance of RISK MANAGEMENT:

• explain the need for correct storage, • safe working practices (risk assessment)
handling, transfer systems and associated • following established procedures
cleanliness control • regular use of diagnostic and test equipment
• regulations and requirements relating to • analysis of results
safe handling and disposal • record keeping

H 2.5.7 Reservoirs and Conditioning b) List common faults and possible causes and
Equipment effects on system performance:
Describe the function of a reservoir and associated • high noise level
fluid conditioning equipment. • vibration
a) Describe a typical reservoir with respect to: • system/component temperature high
• size (relate to pump capacity) with reference to • erratic operations (stick-slip, air
open and closed systems inclusion, cavitation, aeration, dieseling)
• general construction • incorrect pressure
• return line arrangements • incorrect actuator speed
• filling arrangements • failing to work within component manufacturers’
• level/temperature indication recommendations
• contamination control • failure to hold position/load
• leakage
b) Describe methods of fluid cooling:
• reservoir (size, siting) c) Describe procedures that should be followed
• air blast coolers when carrying out fault diagnosis and
• water cooled coolers rectification:
• safe working practices
H 2.5.8 Hydraulic pressure equipment and safety and associated risk assessments
components • identifying the nature of the fault
Describe function, operation and typical applications • identify and remove the cause of the fault and
of accumulator installation. take steps to prevent re- occurrence
• identify information required for
Describe effective fault diagnosis and rectification
• bladder type • use of test equipment and diagnostic techniques
• piston type • use of FCR (fault, cause, remedy) procedures
• diaphragm type • importance of accurate record keeping
• safety components • establishing system restart procedures and
• safety and control features to PED emergency stop procedures
• pre-charge procedures • re-establishing the workplace ”fit for purpose”
• know the difference between preventive
action versus corrective action
52

MOBILE HYDRAULICS & ASSOCIATED CONTROL

PROGRAMME (MH2): RE 2015/06.01 - H
CETOP (Passport) Occupational Level 2

INTRODUCTION • PROACTIVE MAINTENANCE AND MACHINE

MANAGEMENT
This is a LEVEL 2 Hydraulics Programme, • SERVICING
forming the start of a series of competence- • COMPONENT REMOVAL AND
based qualifications designed around CETOP REPLACEMENT
occupational levels.
The development of planning and preparatory
It combines the necessary knowledge and com- skills, the use of technical information and
petence based skills for those people on route specifications and the formulation and
to a higher level qualification at level 3, involving implementation of safe working procedures will
the maintenance and management of both be emphasized throughout all aspects of this
Industrial and Mobile hydraulic systems. programme.

Note: In all cases, each programme represents METHODOLOGY AND ASSESSMENT

a ”stand-alone” qualification but can also be a
progressive route to a higher level. The programme can be offered via a range of
learning modes devised by the Approved Centres
ranging from that of short courses to distance
CETOP OCCUPATIONAL LEVEL 2 learning and centre based modules. The time
scale can also be flexibly managed by the
LEVEL (2) This person will perform a variety of Approved Centres.
activities needing some understanding of the
technical factors involved. The activities may Candidates will be expected to complete a series
require the interpretation and application of var- of assignments throughout the programme of
ied and non-routine specifications. Activities will study to reinforce the learning process and
involve the use of simple diagnostic checks and attend the programme of centre based modules.
ability to make a positive response to
deviations. Co-operation with others in team or Final assessment for the knowledge-- based units
work groups may be required. will be by means of a written examination of 2
hours duration. These will be prepared and offered
Throughout the programme, emphasis is placed at approved centres or at an engaged external
upon the development of knowledge relating to examination centre. The pass mark for the written
”FUNCTION”, ”OPERATION” and ”APPLICA- examination will be 60%.
TION”. The knowledge based section will support
the development and effective application of The expected completion time for this
practical skills necessary to carry out in a safe competence based programme is 1-2 years but
and effective manner: this does depend upon previous experience and
the learning mode devised by the centre and will
• INSTALLATION require a high level of personal commitment to
• COMMISSIONING study and research the subjects within the
• PERFORMANCE TESTING syllabus.

No part of this publication may be photocopied or otherwise reproduced without the prior permission in writing of the Association.
Whilst the Association does its best to ensure that any information that it may give is accurate, no liability or responsibility of any kind is accepted in this respect by the Association,
its members, its servants or agents. Further copies of this document can be obtained from the CETOP, e-mail: [email protected]. PDF-version of this document can be
obtained from the CETOP web-site: www.cetop.org.
 53

Successful completion of both the knowledge Assessment Requirements

based and competence-based units will result in In practical tasks, candidates must on at least
the award of a CETOP Level 2 Mobile two occasions, prove their ability to carry out
Hydraulics Qualification Certificate. (Candidates the following:
successfully completing only one unit might
receive a CETOP Unit Certificate). Assessed Ability
MH2.1 Interpret hydraulic circuit diagrams
No part of this publication may be photocopied or applicable to selected systems.
otherwise reproduced without the prior
permission in writing of the Association. Evidence Required
MH2.1.1 Machine function and operation
Whilst the Association does its best to ensure correctly identified.
that any information it may give is accurate, no MH2.1.2 Components named and function
liability or responsibility of any kind is accepted in identified.
this respect by the Association, its members, its MH2.1.3 Component control methods identified.
servants or agents.
Assessed Ability
PDF-Version of this document can be MH 2.2 Assemble a hydraulic system from
obtained from the CETOP web-site: given information and carry out
www.cetop.org, E-Mail: [email protected] effective fault diagnosis.

Evidence Required
PRACTICAL TASK ASSESSMENT (MH2) MH 2.2.1 Components selected and checked
When assessing competence, the following against specification.
MH 2.2.2 Installation plan prepared
processes must be followed: (order of actions to be taken).
MH 2.2.3 Safe working practices followed at all
• Relating to the occupational level, a series of times.
Assessed Abilities are identified. These repre-
MH 2.2.4 Components commissioned by
sent the ”DOING PART” of a person’s job and
following prescribed procedures.
requires a combination of both practical skills
MH 2.2.5 Start up procedures followed.
and applied knowledge.
MH 2.2.6 System operational checks carried out
and results recorded.
• For each Assessed Ability, evidence of MH 2.2.7 System operates according to
performance is then established and shown as specification.
EVIDENCE REQUIRED (sometimes termed
MH 2.2.8 System fails to operate according to
performance criteria).
specification – ”Fault, Cause, Remedy”
Approach to fault diagnosis is
Practical task assessments to verify effectively applied to re-establish 2.2.7.
competency against the agreed performance
criteria will be carried out at the approved
Assessed Ability
centre during the education programme period. MH 2.3 Pump performance test carried out to
It could be arranged on one to one base or in assess Q/P relationship under
groups, candidate/ candidates to tutor. load conditions.
During practical task assessment, the
Evidence Required
ASSESSOR will agree the ”type of evidence”
MH 2.3.1 Correct diagnostic equipment selected.
to be obtained and this can range from:
MH 2.3.2 Establish test procedures followed.
MH 2.3.3 Safe working practices followed at all
• Direct Observation times.
• Verbal Questioning/Candidate Commentary
MH 2.3.4 Pump specification checked.
• Written Report
MH 2.3.5 Engine speed for test established.
and may include all types.
MH 2.3.6 Performance results recorded and
written report completed covering
all actions taken.
54

Assessed Ability MOBILE HYDRAULICS PROGRAMME

MH 2.4 System contamination levels assessed - (Knowledge Based Unit)
against established target
cleanliness levels. MH2.5.1 Fundamental Hydraulic Principles
and Basic Circuit Configuration
Evidence Required
State and use the fundamental principles
MH 2.4.1 Established oil sampling procedures
underpinning the operation of Hydraulic systems
followed.
and know how they affect performance:
MH 2.4.2 Cleanliness control procedures
followed to ensure representative a) Pascal’s Law (static and dynamic pressure).
sample is taken.
MH 2.4.3 Sample identification procedures b) Know the cause and effect of pressure
followed. generation, pressure losses, heat generation,
MH 2.4.4 Safe working practices followed at all fluid leakage, cavitation, aeration, noise and
times. vibration.
MH 2.4.5 Sample analysis procedures
followed and comparison checks made c) State and use the relationship between:
to determine cleanliness level. • pressure, area and the force transmitted
MH 2.4.6 Written report completed. by a cylinder
• flow rate, cylinder dimensions
and cylinder velocity
MOBILE HYDRAULICS PROGRAMME • pressure, displacement and hydraulic motor
KNOWLEDGE BASED UNIT (MH2) torque
• flow rate, displacement and motor speed
CONTENTS • pump displacement, shaft speed and flow rate
• pump flow rate, operating pressure
MH 2.5.1 Fundamental Principles. and hydraulic power
MH 2.5.2 Hydraulic System Components. • volumetric efficiency, mechanical efficiency
MH 2.5.3 Pumps and Associated Control Systems. and overall efficiency of pumps and motors
MH 2.5.4 Hydraulic Actuators. • pipe diameters, flow rates, fluid viscosity
MH 2.5.5 Circuitry and Control Features. and pressure losses
MH 2.5.6 Hydraulic Fluids.
MH 2.5.7 Reservoirs and Auxiliary Equipment. d) Outline the basic building blocks and circuit
MH 2.5.8 Contamination Control. configuration for a typical mobile machine:
MH 2.5.9 Maintenance, Monitoring • engine
and Fault Finding. • main and auxiliary pumps
• reservoir and fluid
• steering and braking systems
KNOWLEDGE BASED UNIT – • valve control systems
WRITTEN EXAMINATION SPECIFICATION • motors and actuators
• filters and coolers
The examination paper will contain questions • pipe work, rigid and flexible
from all sections of the programme.
MH 2.5.2 Hydraulic System Components
• Examination minimum duration 2 consecutive Describe the function and operation of control
hours valves and recognize their graphical symbols on
• Pass mark 60% associated circuitry.
• Question style may be single subject, multiple
subject, short answer and multiple choice a) Flow control:
• All questions will carry equal marks • flow control devices both fixed and adjustable
• pressure and temperature compensated flow
Where calculations and formulae are control devices
involved, all stages of the calculation together • flow dividers – spool, rotary and priority
with their corresponding units must be shown.
b) Pressure control:
• relief valves – single and two stage
• vented vent control and unloading principles
 55

• pressure reducing (two way and three way MH 2.5.4 Hydraulic Actuators
operations) Describe function and operation of
• joystick control Hydraulic actuators.
• sequence valves
a) Motor types:
c) Load Holding and Motion Control: • gear
• pilot operated check valves • gerotor/orbit
• counterbalance with remote pilot • vane
• hose burst valves • radial piston – single and two speed
• axial piston – fixed and variable displacement
d) Directional Control devices and methods of • bent axis – fixed and variable displacement
control (including proportional control):
• multiple port mobile valve (open and closed b) Motor performance:
center including load sensing arrangements, • series circuitry
involving pre-compensation) • parallel circuitry
• control methods including manual, oil pilot
and Electro-Hydraulic c) Cylinders, types, construction, sealing
• spool valves – including two stage configurations and mounting arrangements:
to ISO standards • single acting
• poppet valves • double acting
• rotary valves • telescopic
• manual/pilot/on-off solenoid operation and • sealing
proportional control • mounting arrangements
• cushioning
MH 2.5.3 Pumps and Associated Control Systems
Describe the function and operation of d) Semi-rotary actuators:
Hydraulic pumps and listed control systems, • rack and pinion type
plus set up procedures as prescribed. • vane type

a) Pumps: MH 2.5.5 Circuitry and Control Features

• external gear Interpret listed circuitry and associated drive
• internal gear systems.
• gerotor
• vane (fixed and variable) a) counterbalance and load holding
• axial piston (fixed and variable)
• bent axis (fixed and variable) b) closed hydrostatic circuitry including:
• pump control features
b) Control features: • motor control features
• fixed pumps with relief
valve involving vent control c) two pump unloaded valve circuit
• unloading (two pump system)
• pressure compensation with d)pump control circuit including pressure
and without load sensing compensation, load sensing and constant
• manual displacement control power/torque
• constant power control
e) hydrostatic steering circuitry (non-dynamic)
c) Pump relationship between pressure including:
and flow (Q/P) characteristics. • open center
• closed center
d) Compensator setting up procedures involving
standby and pressure limiting compensators. f) mobile valve circuitry involving joystick pilot oil
control, including:
e) Effects of engine speed • open center valve spool arrangements
on pump performance. • closed center valve spool arrangements
56

g) braking circuitry involving: b) Describe methods of fluid cooling:

• parking brakes • reservoir (size, siting)
• service brakes • air blast coolers
• water cooled coolers
h) regenerative circuitry
c) Describe function, operation and typical
i) power take off arrangements for pump applications of Accumulators:
transmission applying step up/step down • bladder type
gearbox • piston type
• diaphragm type
MH 2.5.6 Hydraulic Fluids
• safety and control features
Describe the functions and characteristics of
• pre-charge procedures
hydraulic fluids.
a) Functions: MH 2.5.8 Contamination Control
• power transmission Describe contamination control methods.
• lubrication
• cooling • origins of contamination
• sealing • cleanliness targets – achieving and maintaining
• carrier for contaminants • monitoring fluid condition
(sampling and measurement)
b) Characteristics and properties and their effect • preventive/correction actions
on system performance: • filter performance and ratings
• viscosity • filter types
• viscosity index • locations and performance
• lubricity
• oxidation MH 2.5.9 Maintenance, Monitoring and Fault Finding
• pour point Procedures
• demulsibility Describe maintenance, monitoring and
• material compatibility fault finding procedures.

c) Oil types and application: a) Know the importance of RISK MANAGEMENT:

• mineral oil • safe working practices (risk assessment)
• glycols • following established procedures
• bio-degradable fluids • regular use of diagnostic and test equipment
• engine oils (SAE grades) • analysis of results
• transmission fluids • record keeping

d) Storage, handling and transfer: b) List common faults and possible causes and
• explain the need for correct storage, handling, effects on system performance:
transfer systems and associated cleanliness • high noise level
control • vibration
• COSHH regulations and requirements relating • system/component temperature high
to unsafe handling and disposal • erratic operations (stick-slip, air inclusion,
cavitation, aeration, dieseling)
MH 2.5.7 Reservoirs and Auxiliary Equipment • incorrect pressure
Describe the function of a reservoir and associ- • incorrect actuator speed
ated fluid conditioning equipment and auxiliary • failing to work within component manufacturers’
components. recommendations
• failure to hold position/load
a) Describe a typical reservoir with respect to: • leakage
• size (relate to pump capacity) with reference to
open and closed systems c) Describe procedures that should be followed when
• general construction carrying out fault diagnosis and rectification:
• return line arrangements
• filling arrangements • safe working practices and associated risk
• level/temperature indication assessments
• contamination control • identifying the nature of the fault
 57

• identify and remove the cause of the fault and take • importance of accurate record keeping
steps to prevent re-occurrence • establishing system restart procedures and
• identify information required for effective fault emergency stop procedures
diagnosis and rectification • re-establishing the workplace ”fit for purpose”
• use of test equipment and diagnostic techniques • know the difference between preventive
• use of FCR (fault, cause, remedy) procedures action versus corrective action

INDUSTRIAL HYDRAULICS & ASSOCIATED

CONTROL PROGRAMME (IH2) CETOP RE 2015/06.01 - H
CETOP (Passport) Occupational Level 2

INTRODUCTION • INSTALLATION
• COMMISSIONING
This is a LEVEL 2 Hydraulics Programme, • PERFORMANCE TESTING
forming the start of a series of competence-based • PROACTIVE MAINTENANCE AND MACHINE
qualifications designed around CETOP occupational MANAGEMENT
levels. • SERVICING
• COMPONENT REMOVAL AND
It combines the necessary knowledge and REPLACEMENT
competence based skills for those people on route
to a higher level qualification at level 3, involving the The development of planning and preparatory
maintenance and management of both Industrial and skills, the use of technical information and
Mobile hydraulic systems. specifications and the formulation and
implementation of safe working procedures will
Note: In all cases, each programme represents a be emphasized throughout all aspects of this
”stand-alone” qualification but can also be a programme.
progressive route to a higher level.
METHODOLOGY AND ASSESSMENT

CETOP OCCUPATIONAL LEVEL 2 The programme can be offered via a range of

learning modes devised by the Approved
LEVEL (2) This person will perform a variety of Centres ranging from that of short courses to
activities needing some understanding of the technical distance learning and centre based modules.
factors involved. The activities may re- quire the The time scale can also be flexibly managed
interpretation and application of varied and non- by the Approved Centres.
routine specifications. Activities will involve the use of
simple diagnostic checks and ability to make a Candidates will be expected to complete a se-
positive response to deviations. Co-operation with ries of assignments throughout the programme of
others in team or work groups may be required. study to reinforce the learning process and
attend the programme of centre based modules.
Throughout the programme, emphasis is placed upon
the development of knowledge relating to Final assessment for the knowledge-- based units
”FUNCTION”, ”OPERATION” and ”APPLICA- will be by means of a written examination of 2 hours
TION”. The knowledge based section will support the duration. These will be prepared and offered at
development and effective application of practical skills approved centres or at an engaged external
necessary to carry out in a safe and effective manner: examination centre. The pass mark for the written
examination will be 60%.

No part of this publication may be photocopied or otherwise reproduced without the prior permission in writing of the Association.
Whilst the Association does its best to ensure that any information that it may give is accurate, no liability or responsibility of any kind is accepted in this respect by the Association,
its members, its servants or agents. Further copies of this document can be obtained from the CETOP, e-mail: [email protected]. PDF-version of this document can be
obtained from the CETOP web-site: www.cetop.org.
58

The expected completion time for this • Direct Observation

competence based programme is 1-2 years but • Verbal Questioning/Candidate Commentary
this does de-pend upon previous experience • Written Report
and the learning mode devised by the centre and may include all types.
and will require a high level of personal
commitment to study and re-search the subjects Assessment Requirements
within the syllabus. In practical tasks, candidates must on at least two
occasions, prove their ability to carry out the
Successful completion of both the knowledge- following:
based and competence-based units will result in
the award of a CETOP Level 2 Industrial Assessed Ability
Hydraulics Qualification Certificate. (Candidates IH2.1 Interpret hydraulic circuit diagrams
successfully completing only one unit might applicable to selected systems.
receive a CETOP Unit Certificate).
Evidence Required
No part of this publication may be IH 2.1.1 Machine function and operation correctly
photocopied or otherwise reproduced without identified.
the prior permission in writing of the IH 2.1.2 Components named and function
Association. identified.
IH2.1.3 Component control methods identified.
Whilst the Association does its best to ensure
that any information it may give is accurate, no Assessed Ability
liability or responsibility of any kind is accepted IH2.2 Assemble a hydraulic system from given
in this respect by the Association, its information and carry out effective
members, its servants or agents. fault diagnosis.

PDF version of this document can be obtained Evidence Required

on the CETOP web-site: www.cetop.org IH 2.2.1 Components selected and checked
e-mail: [email protected] against specification.
IH 2.2.2 Installation plan prepared
PRACTICAL TASK ASSESSMENT (IH2) (order of actions to be taken).
IH 2.2.3 Safe working practices followed
When assessing competence, the at all times.
following processes must be followed: IH 2.2.4 Components commissioned by following
• Relating to the occupational level, a prescribed procedures.
series of Assessed Abilities are identified. IH 2.2.5 Start up procedures followed.
These represent the ”DOING PART” of a IH 2.2.6 System operational checks carried out
person’s job and requires a combination and results recorded.
of both practical skills and applied IH 2.2.7 System operates according to specification.
knowledge. IH 2.2.8 System fails to operate according to
• For each Assessed Ability, evidence of specification – ”Fault, Cause, Remedy”
perform- ance is then established and shown Approach to fault diagnosis is effectively
as EVIDENCE REQUIRED (sometimes
applied to re-establish 2.2.7.
termed performance criteria).

Practical task preparation and competence- Assessed Ability

based unit assessment will be carried out by IH2.3 Pump performance test carried out
arrangement with the approved centre during to assess Q/P relationship under
the year. Final assessment will be carried out on load conditions.
a ”one to one” basis, candidate to tutor, and the
outcome will be pass or fail. Evidence Required
IH 2.3.1 Correct diagnostic equipment selected.
During practical task assessment, the IH 2.3.2 Establish test procedures followed.
ASSESSOR will agree the ”type of evidence” IH 2.3.3 Safe working practices followed at all times.
to be obtained and this can range from: IH 2.3.4 Pump specification checked.
 59

IH 2.3.5 Performance results recorded and written INDUSTRIAL HYDRAULICS PROGRAMME

report completed covering all - (Knowledge Based Unit)
actions taken.
IH 2.5.1 Fundamental Hydraulic Principles
Assessed Ability State and use the fundamental principles
IH 2.4 System contamination levels assessed underpinning the operation of Hydraulic systems
against established target and know how they affect performance:
cleanliness levels.
a) Pascal’s Law (static and dynamic pressure).
Evidence Required
IH2.4.1 Established oil sampling procedures b) Know the cause and effect of pressure ge-
followed. neration, pressure losses, heat generation, fluid
IH2.4.2 Cleanliness control procedures followed to leakage, cavitation, aeration, noise and
ensure representative sample is taken. vibration.
IH2.4.3 Sample identification procedures followed.
IH2.4.4 Safe working practices followed at all c) State and use the relationship between:
times. • pressure, area and the force transmitted by a
IH2.4.5 Sample analysis procedures followed and cylinder
comparison checks made to determine • flow rate, cylinder dimensions
cleanliness level. and cylinder velocity
IH2.4.6 Written report completed. • pressure, displacement and hydraulic motor
torque
• flow rate, displacement and motor speed
INDUSTRIAL HYDRAULICS PROGRAMME • pump displacement, shaft speed and flow rate
KNOWLEDGE BASED UNIT (IH2) • pump flow rate, operating pressure
and hydraulic power
CONTENTS • volumetric efficiency, mechanical efficiency
and overall efficiency of pumps and motors
IH2.5.1 Fundamental Principles. • pipe diameters, flow rates, fluid viscosity
IH2.5.2 Hydraulic System Components. and pressure losses
IH2.5.3 Pumps and Associated Control Systems.
IH2.5.4 Hydraulic Actuators. IH 2.5.2 Hydraulic System Components
IH2.5.5 Circuitry and Control Features. Describe the function and operation of control
IH2.5.6 Hydraulic Fluids. valves and recognize their graphical symbols on
IH2.5.7 Reservoirs and Auxiliary Equipment. associated circuitry.
IH2.5.8 Contamination Control.
IH2.5.9 Maintenance, Monitoring and Fault Finding. a) Flow control:
• flow control devices both fixed and adjustable
• pressure and temperature compensated flow
KNOWLEDGE BASED UNIT – control devices
WRITTEN EXAMINATION SPECIFICATION • flow dividers – spool, rotary and priority

The examination paper will contain questions from b) Pressure control:

all sections of the programme. • relief valves – single and two stage
• vented vent control and unloading principles
• Examination minimum duration 2 consecutive • pressure reducing – single and two stage (two
hours way and three way operations)
• Pass mark 60% • counterbalance with remote pilot
• Question style may be single subject, multiple • sequence valves
subject, short answer, multiple choice
• All questions will carry equal marks c) Directional Control devices
and methods of control:
Where calculations and formulae are involved, all • check valves
stages of the calculation together with their • pilot operated check valves
corresponding units must be shown. • spool valves – including two stage
• poppet valves
• rotary valves
60

• manual/pilot/on-off solenoid operation d) Semi-rotary actuators:

• introduction to proportional control • rack and pinion type
• vane type
IH 2.5.3 Pumps and Associated Control Systems • others

Describe the function and operation of Hydraulic IH 2.5.5 Circuitry and Control Features
pumps and listed control systems, plus set up Interpret listed circuitry, including basic electrical
pro-cedures as prescribed. symbols and circuits.

a) Pumps: • counterbalance
• external gear • regenerative circuit
• internal gear • two pump (Hi-Lo) circuits
• gerotor • sequence valve circuitry
• vane (fixed and variable) • P O checks. (Load holding, pre-fill/decompression)
• axial piston (fixed and variable) • closed hydrostatic circuitry
• bent axis (fixed and variable)
• radial piston (fixed and variable)
a) Electrical symbols and associated circuitry:
b) Control features: • NO and NC contacts
• fixed pumps with relief valve • solenoids (AC and DC)
involving vent control • relays
• unloading (two pump system)
• pressure compensation with IH 2.5.6 Hydraulic Fluids
and without load sensing Describe the functions and
• manual displacement control characteristics of hydraulic fluids.

c) Pump relationship between pressure and a) Functions:

flow (Q/P) characteristics. • power transmission
• lubrication
d) Compensator setting up procedures involving • cooling
standby and pressure limiting compensators. • sealing
• carrier for contaminants
IH 2.5.4 Hydraulic Actuators
Describe function and operation of b) Characteristics and properties and their effect
hydraulic actuators. on system performance:
• viscosity
a) Motor types: • viscosity index
• gear • lubricity
• gerotor/orbit • oxidation
• vane • pour point
• radial piston – single and two speed • demulsibility
• axial piston – fixed and variable displacement • material compatibility
• bent axis – fixed and variable displacement
c) Oil types and application:
b) Motor performance: • mineral oil
• series circuitry • emulsions
• parallel circuitry • glycols
• bio-degradable fluids
c) Cylinders, types, construction, sealing and
mounting arrangements: d) Storage, handling and transfer:
• single acting • explain the need for correct storage, handling,
• double acting transfer systems and associated cleanliness
• through rod control
• sealing • regulations and requirements relating to
• mounting arrangements safe handling and disposal
• cushioning
 61

IH 2.5.7 Reservoirs and Auxiliary Equipment IH 2.5.9 Maintenance, Monitoring and

Describe the function of a reservoir and associ- Fault Finding Procedures
ated fluid conditioning equipment and auxiliary Describe maintenance, Monitoring and fault
components. finding procedures.

a) Describe a typical reservoir with respect to: a) Know the importance of RISK MANAGEMENT:
• size (relate to pump capacity) • safe working practices (risk assessment)
• general construction • following established procedures
• return line arrangements • regular use of diagnostic and test equipment
• filling arrangements • analysis of results
• level/temperature indication • record keeping
• contamination control
b) List common faults and possible causes
b) Describe methods of fluid cooling: and effects on system performance:
• reservoir (size, siting) • high noise level
• air blast coolers • vibration
• water cooled coolers • system/component temperature high
• erratic operations (stick-slip, air inclusion,
c) Describe function, operation and typical cavitation, aeration, dieseling)
applications of accumulators: • incorrect pressure
• bladder type • incorrect actuator speed
• piston type • failing to work within component manufacturers’
• diaphragm type recommendations
• safety and control features • failure to hold position/load
• pre-charge procedures • leakage

IH 2.5.8 Contamination Control c) Describe procedures that should be followed

Describe contamination control methods. when carrying out fault diagnosis
and rectification:
• origins of contamination • safe working practices
• cleanliness targets – achieving and maintaining and associated risk assessments
• monitoring fluid condition • identifying the nature of the fault
(sampling and measurement) • identify and remove the cause of the fault
• preventive/correction actions and take steps to prevent re-occurrence
• filter performance and ratings • identify information required for effective
• filter types fault diagnosis and rectification
• locations and performance • use of test equipment and diagnostic techniques
• use of FCR (fault, cause, remedy) procedures
• importance of accurate record keeping
• establishing system restart procedures
• re-establishing the workplace ”fit for purpose”
• preventive versus corrective action
 62

HYDRAULICS & ASSOCIATED CONTROL

PROGRAMME (H3): RE 2015/06.01 - H
CETOP (Passport) Occupational Level 3

INTRODUCTION METHODOLOGY AND ASSESSMENT

This is a LEVEL 3 Hydraulics Programme, The programme can be offered via a range of
forming the start of a series of competency- learning modes devised by the Approved Centres
based qualifications designed around CETOP but it is envisaged that distance learning supported
occupational levels. by a series of centre based modules will be the
It combines the necessary knowledge and normal system used.
competency based skills for those people on
route to this high level of qualification, involving Candidates will be expected to complete a series
the maintenance and management of both of assignments throughout the programme of study
Industrial and Mobile hydraulic systems. to reinforce the learning process and attend the
programme of centre based modules.
CETOP OCCUPATIONAL LEVEL 3
Final assessment for the knowledge-- based units
LEVEL (3) This person will be involved in a will be by means of a written examination of 2½
broad and often complex range of activities, hours duration. These will be prepared and
often requiring independent decisions to be offered at approved centres or at an engaged
made on technical matters concerning external examination centre. The pass mark for
specifications, resources or processes. the written examination will be 70%.
Planning of work will be a responsibility, as will
the finding and rectification of faults. The expected completion time for a competency
Responsibility for the quality of work undertaken based programme is one to three years depending
and the required outcomes are also included. on work experience within hydraulics and will require
a high level of personal commitment to study and
Throughout the programme, emphasis is placed research the subjects within the syllabus.
upon the development of knowledge relating to
“FUNCTION”,”OPERATION” and ”APPLICATION”. Practical task assessments to verify competency
The knowledge based section will support the against the agreed performance criteria will be
development and effective application of carried out at the approved centre during the
practical skills necessary to carry out in a safe education programme period. It could be arranged
and effective manner: on one to one base or in groups, candidate/
candidates to tutor.
• INSTALLATION
• COMMISSIONING All candidates taking a level 3 qualification should
• PERFORMANCE TESTING have a minimum of 2 years work based experience
• PROACTIVE MAINTENANCE AND involving hydraulics verified by their employer.
MACHINE MANAGEMENT
• SERVICING Alternative:
• COMPONENT REMOVAL AND Where candidates do not have 2 years work based
REPLACEMENT experience they can undertake the qualification but
will not receive the award until they have completed
The development of planning and preparatory two years of verified employment involving
skills, the use of technical information and hydraulics.
specifications and the formulation and
implementation of safe working procedures will Successful completion of both the knowledge based
be emphasized throughout all aspects of this and competency based units will result in the award
programme. of a CETOP Level 3 Hydraulics Qualification
Certificate. Candidates successfully completing only
one unit will receive a CETOP Unit Certificate.

No part of this publication may be photocopied or otherwise reproduced without the prior permission in writing of the Association.
Whilst the Association does its best to ensure that any information that it may give is accurate, no liability or responsibility of any kind is accepted in this respect by the Association, its
members, its servants or agents. Further copies of this document can be obtained from the CETOP, e-mail: [email protected]. PDF-version of this document can be obtained from the
CETOP web-site: www.cetop.org.
 63

PRACTICAL TASK ASSESSMENT (H3) Evidence Required

H3.3.1 Nature of fault correctly identified.
Assessment Requirements H 3.3.2 Fault, cause, remedy checklist prepared.
In practical tasks, candidates must on at least two H 3.3.3 Diagnostics used to locate fault.
occasions, prove their ability to carry out the H 3.3.4 Safe working practices followed at all
following: times.
H 3.3.5 Faulty components replaced.
Assessed Ability H 3.3.6 Cause and effect of faults assessed.
H 3.1 Interpret hydraulic and Electro-Hydraulic H 3.3.7 System re-commissioned in accordance
circuit diagrams applicable to selected with set procedures.
systems (against recommended specification) H 3.3.8 System operated according to machine
and prepare a schematic representation of the specification.
system.
Assessed Ability
Evidence Required
H 3.4 Designated or faulty component
H 3.1.1 Machine function and operating principles
replacement carried out in accordance
identified.
with given information.
H3.1.2 Components correctly identified.
H3.1.3 Function and operation of individual sub-
Evidence Required
circuits correctly identified.
H 3.4 Establish documented procedures and
H3.1.4 Machine control inputs and outputs
carry out proactive maintenance and
identified.
monitoring of Electro-Hydraulic systems.
Assessed Ability
H 3.2 Assemble a hydraulic system from given Evidence Required
information and establish suit- able H 3.4.1 System assessed to determine
maintenance procedures. service/maintenance schedule
requirements.
Evidence Required H 3.4.2 System assessed to determine routine
H 3.2.1 Components selected and conformance monitoring requirements.
checked against system specification. H 3.4.3 Documented system established including
H 3.2.2 Installation plan prepared. safety requirements/risk assessment.
H3.2.3 System assembled in a safe and efficient H 3.4.4 Performance testing carried out and
manner. results recorded.
H 3.2.4 Commissioning procedures followed in H 3.4.5 Electrical input and output signals
accordance with technical specification. involving on-off and proportional control
H 3.2.5 Startup procedures correctly specified and systems checked and recorded.
followed. H 3.4.6 Fluid sampling carried out and
H 3.2.6 System operated according to contamination levels assessed against
specification. target cleanliness and result recorded.
H 3.2.7 Establish predictive maintenance H 3.4.7 Manufacturers recommendations and
procedures to be followed, including: specifications checked against results.
• component performance testing H 3.4.8 Safe working practices followed at all
• fluid sampling and assessment of times.
contamination level against target level. H 3.4.9 Work place re-established to required
• electrical input and output signals levels of tidiness and cleanliness.
involving on/off and proportional control
systems Note: Preparation for practical task
assessment can be a group activity or it
Assessed Ability could be carried out on a ”one to one ”
H 3.3 Carry out effective fault diagnosis and basis between the candidate and the
rectification. assessor. Evidence will be obtained by non-
intrusive observation, questioning or
written and verbal reports.
64

KNOWLEDGE BASED SECTION (H3) CONTENTS H 3.5.1 Fundamental and Scientific Principles
Describe the fundamental principles of power
H 3.5.1 Fundamental and Scientific Principles
transmission by hydraulics and associated scientific
H 3.5.2 Application of the Fundamental Principles principles underlying its use.
H 3.5.3 Hydraulic Fluids
H 3.5.4 Valve Mounting Styles/Configurations a) List the basic building blocks and describe their
H 3.5.5 Control Valves function with reference to:
H 3.5.6 Mobile multifunction Valves prime movers, pumps, reservoirs, fluids, control
H 3.5.7 Hydrostatic Steering Systems valves, filters, coolers, pipe work and manifold
H 3.5.8 Slip-in Logic Cartridge Valves blocks.
H3.5.9 Fundamental Electrical Principles
H 3.5.10 Electrical/Electronic Components b) Know the cause and effect of pressure
H 3.5.11 Proportional Valve Technology generation, pressure losses, heat generation, fluid
H 3.5.12 Electronic controls and sensors leakage, cavitation, aeration, noise and vibration.
H 3.5.13 Pumps and Associated Control Systems
H 3.5.14 Hydraulic Actuators (Motors and c) Know the difference between laminar
Cylinders) and turbulent flow and their effect on
H 3.5.15 Closed Hydrostatic Transmissions H system performance.
3.5.16 Reservoirs, Conditioning and
Auxiliary Components d) Know the meaning of the term Reynolds Number
H 3.5.17 Hydraulic pressure equipment and safety and use the associated formula.
components
H 3.5.18 Pipes and Hoses - Installation and e) Know the difference between static and
Commissioning Procedures dynamic pressure.
H 3.5.19 Contamination Control
H 3.5.20 Machine Circuitry and Control Features f) Know the quantities and units:
(Recognition and use of hydraulics and pressure, force, area, displacement, flow rate,
electrical symbols) speed/velocity, torque and power.
H 3.5.21 Installation and Commissioning Procedures
H 3.5.22 Maintenance, Monitoring and Fault Finding g) Know the formulae relating to:
Procedures pressure, force, area, displacement, flow rate,
speed/velocity, torque and power.

KNOWLEDGE BASED UNIT – WRITTEN h) Know the principles of heat dissipation and
temperature control:
EXAMINATION SPECIFICATION heat sinks within a system (reservoirs, pipe work
and coolers) and effects of ambient conditions and
The examination paper will contain 8 questions in- working cycle.
tegrating the above 22 sections
i) State and use the relationship between: pressure,
• Examination duration will be 2½ consecutive hours force and area for cylinders and pressure, torque
• Candidates will be expected to attempt 5 questions and displacement per revolution for pumps and
• Each question will carry equal marks motors.
• Pass mark will be 70%
j) State and use the relationship between:
Where calculations and formulae are involved, all flow, area and velocity for cylinders, and flow,
progressive stages of the calculation together with the displacement per revolution and shaft speeds for
corresponding units must be shown pumps and motors.

k) Know the relationship between:

HYDRAULICS PROGRAMME input and output powers of pumps and motors and
(Knowledge Based Section) the causes of volumetric and mechanical
In addition to demonstrating an understanding of inefficiencies.
Hydraulic Systems and Associated Control,
candidates must prove ability to:
 65

H 3.5.2 Application and Fundamental d) Fluid selection for typical applications (factors to be
Principles considered):
Describe the application of the fundamental • environmental considerations
principles with regard to:
• fire resistance
• toxicity
a) Relationship between flow rate, pressure
• water separation
drop, restriction, power and heat.
• filterability

b) Control of pressure e) Fluid storage, handling and transfer:

• pressure generation • explain the need for correct storage, handling,
• pressure limiting cleanliness control and transfer systems to be in place
• pressure unloading and controlled by working procedures
• pressure reducing
• pressure intensification f) Explain the need for cleanliness control systems to
be in place and associated fluid analysis procedures
c) Control of flow
and monitoring
• non-compensated flow control
• pressure compensated flow control
• temperature compensated flow control H 3.5.4 Valve Mounting Styles/Configurations
• flow dividing Describe valve mounting styles, standardized interfaces,
• regenerative flow sizes, flow rates, port layouts and sealing arrangements,
• damping relating to:
• meter-in, meter-out and by-pass flow control
• pipe mounting/line mounting
d) Control of movement • sub-plate mounting
• acceleration and deceleration control • manifold mounting
• stopping or preventing movement • stack, mounting
• changing direction • flange mounted valves
• screw in cartridge
H 3.5.3 Hydraulic Fluids • slip in cartridge
Describe the application and selection of fluids • ISO interface valves
for use in hydraulic systems relating to:
H 3.5.5 Control Valves
a) Functions Describe the function, operation and application of
• power transmission control valves and interpret their graphical symbols.
• lubrication
• cooling a) Flow control devices (fixed and adjustable:
• non-compensated flow control devices (orifices and
b) Characteristics and properties (behavior and throttle valves)
effect on system performance): • pressure and temperature compensated flow control
• viscosity valves
• viscosity index • hydrostatics and applications with proportional
• lubrication controls
• thermal stability (oxidation) • priority valves
• pour point • spool flow dividers
• remissibility • rotary flow dividers
• shear stability • differential lock units
• compressibility
• material compatibility b) Pressure control devices:
• foaming and aeration resistance • pressure limiting
• filterability • single stage, relief valves
• specific gravity • two stage, pilot operated relief valves
• fire-resistance • unloading valves
• control features
c) Types of fluids in common use in hydraulic • vent
applications • remote control (manual/proportional)
• ISO/SAE viscosity grades • load sensing
• classifications to ISO standards • pressure sensing (application of pressure switches)
66

• pressure reducing • load holding

• single stage and two stage pressure • anti-cavitation
reducing valves • pressure limiting
• two way and three way configuration
e) Valve characteristics:
c) Load Holding and Motion Control: • valve sizes, flow rates and associated
• pilot operated check valves pressure drops
• counterbalance with internal and external pilot • operating performance (under conditions of
control (including the effect of pilot ratios) closed, partially open and fully open)
• hose burst control devices
H 3.5.7 Hydrostatic Steering Systems
d) Direction control devices: Describe the function, operation and application of
• check valves hydrostatic steering systems and associated control
• pilot operated check valves features:
• spool valves
• ball valves a) Rotary servo steering units:
• poppet valves • open center
• sequence valves • closed center
• reaction and non-reaction types
e) Control features to include simple on-off and • load sensing systems
proportional control) • steer units for electric motor applications
• steer units with ‘power beyond’ facilities
H 3.5.6 Mobile multifunction Valves • flow amplifiers
Describe the function, operation, application and • dual displacement steer units
control features of mobile multifunction control
valves and interpret their graphical symbols. b) Priority valves:
• non dynamic types
a) Mobile spool direction control valves: • dynamic types
• layout/construction (monoblock/sandwich)
• spool configurations (single and multiple) c) Steering systems, modes:
series • single ram single rod, single ram double rod, double
• flow paths - parallel, series and tandem rams single rods
arrangements including carry-over and • methods of switching between steering modes
alternative inlet sections
• open centre, closed center, single acting, d) Emergency steering systems
double-acting motor half motor, regeneration (manual and powered)
and float arrangements
H 3.5.8 Slip-in Logic Cartridge Valves
b) Inlet sections: Describe the function, operation and application Slip-
• pressure control/unloading facilities/priority in (logic) cartridge elements
• load sensing connections
• pilot fluid supply • construction and manifold assembly
• sizes and associated flow rates
c) Controls: • operating principles
• manual - spring cantered, mechanical hydraulic • application for pressure, flow and direction control
and electrical detent including associated control methods
• solenoid and solenoid pilot
• proportional control (with and without spool
H 3.5.9 Fundamental Electrical Principles
position monitoring)
Describe the fundamental principles and control,
• remote control [Joystick], (hydraulic and
applicable to the use and application of electrical/
pneumatic)
electronic technology.
• remote control - electrical [Joystick]
• state and use the relationship between
d) Special features (including inlet, outlet voltage, current, resistance and power
and service ports):
• state the relationship between movement,
• flow sharing (pre and post compensation) magnetism and current
• load sensing, pressure limiting and
• meaning of the term inductance and its effect upon
vent control
DC circuits
 67

• meaning of the term capacitance and its effect H 3.5.12 Electronic controls and sensors
upon DC circuits Describe and interpret electronic controls and
• meaning of the terms amplitude, frequency, periodic sensor signals including functional safety standards:
time and RMS
• define the terms digital and analogue associated Recognize different control signals and functions
with control systems that will be used in industrial machines
• describe the fundamental principles of open and
closed loop control • Types and use of digital BUS systems
• Types and use of different control signals
H 3.5.10 Electrical/Electronic Components (analog, digital)
Describe the function and application of electrical/ • Types and use of different sensor signals
electronic components • Functional Safety standards:
Know the requirements aim of IEC and EN
• resistors standards
• capacitors
• potentiometers H 3.5.13 Pumps and Associated Control Systems
• transformers Describe the function and operation of hydraulic open
• diodes loop pumps and associated control features:
• switches (two way and three way)
• relays a) Pumps:
• proximity and limit switches • external gear
• pressure switches • internal gear
• position sensors • vane (fixed and variable)
• tacho-generator • radial piston (fixed and variable)
• frequency control of electric motor speed • axial piston (fixed and variable)
• bent axis piston (fixed and variable)
H 3.5.11 Proportional Valve Technology • multiple pumps
Describe the principles of proportional valve
technology b) Know the power - torque relationship between
the prime mover and pump with reference to
• list the potential benefits compared to application of electric motor/engine speed.
“on-off“ operated systems
• describe the difference in performance of a c) Control features:
proportional solenoid to that of a standard solenoid • fixed pumps with integral pressure and flow
• describe the application of proportional control to control
pressure, flow and direction control (including • fixed pumps with unloaded valve systems
feedback and non-feedback valves, direct and two • mechanical/hydraulic servo displacement
stage versions) • Electro-Hydraulic proportional displacement
• describe, in block diagram form the control • pressure compensation/limiting
components of a typical proportional valve electronic • load sensing (constant flow/variable speed)
amplifier • constant power
• explain the meaning of the terms: gain adjustment, • torque summation control, including prime mover
dead band compensation, ramp control, dither and characteristics
pulse width modulation and demonstrate an • pumps with frequency control of electric motor
understanding of their effects on system speed and features
performance
• explain the recommended practices for installing d) Link to prime mover:
proportional electronic control in terms of: power • power take off arrangements
supply requirements, enable signals, input signal • splitter gearbox
generation, cable shielding, earthling and interface • step up and step down gearbox arrangements
with PLC’s • belt drives and clutch arrangements
68

H 3.5.14 Hydraulic Actuators (Motors and Cylinders) b) Over center piston pumps:
Describe the function, operation and application of • basic construction (axial, bent axis and radial)
hydraulic actuators, including control features: • control methods
• mechanical
a) Motors: • mechanical servo
• gear • pilot pressure
• gerotor/orbit • electronic servo
• vane • pressure/limitation and displacement control
• radial piston • automotive control
Including variable and dual displacement control
features and associated torque speed characteristics c) Charge pump:
• axial piston (swash plate) • construction
Including variable and dual displacement control • charge pump circuitry
features and associated torque speed characteristics • case flushing (including cooling and heating
• bent axis functions)
Including variable and dual displacement control
features and associated torque speed characteristics d) Control valves:
• cam/roller types • hot oil shuttle valves
Including variable and dual displacement control • cross-line relief valves
features and associated torque speed characteristics • counterbalance valves
• free-wheel by-pass valves
b) Motor features: • differential lock valves
• pressure control (pressure compensation) • parking brake systems
• displacement (torque/speed control)
• parking brake e) Special control features:
• dynamic braking (use of counterbalance valves) • inch control
• creep speed
c) Motor performance: • brake defeat function
• series circuitry • hydrostatic braking
• parallel circuitry
H 3.5.16 Reservoirs, Conditioning and Auxiliary
d) Cylinders, mounting arrangements and Components
construction: Describe the purpose of the system reservoir and
• telescopic associated fluid conditioning equipment and auxil-
• single acting iary components.
• double acting
• sealing a) Outline a typical system reservoir in terms of:
• cushioning • size, with reference to oil and air space and
• mounting arrangements changes in level
• position monitoring • general construction (internal/external), incl. return
line and port arrangements to minimize aeration)
e) Semi-rotary actuators: • level/temperature indication
• rack and pinion type • filling connections
• vane type • sampling points
• level/temperature indication
H 3.5.15 Closed Loop Hydrostatic Transmissions • air and oil filtration
Describe the function, operation and application of • pressurized reservoirs
hydraulic components associated with closed loop • use of bladder and diaphragms separators
hydrostatic transmission systems: b) Describe the use of hydraulic fluid systems:
• cooling
a) Basic configuration: • reservoirs (size, siting and layout)
• close coupled (motor and pump back to back units) • air blast coolers
• water coolers
 69

H 3.5.17 Hydraulic pressure equipment and safety • flow rate

components • fluid viscosity and density
Describe the function, operation and application of • component size/ design
hydraulic accumulators, associated safety components
and associated selection process and sizing relating to d) Hoses types and application:
application: • wire braided
• 2-wire braided
a) Accumulator: • spiral wire
• piston • thermoplastic
• bladder • high temperature and protective sleeved
• diaphragm (abrasion resistant)
• low temperature
b) Associated Safety component and control features
Fluid side: e) Hose/pipe fitting and assembly procedures:
• pressure relief valve • use of adapters and unions,
• safety block • use of bite compression fittings
• pressure switches • use of ‘O-Ring’ fittings
• use of flange type fittings
Gas side: • use of formed fittings
• pressure relief valve • use of welded connections
• temperature fuse
• burst disc f) Hydraulic hose failures relating to:
• pressure switches • poor installation procedures
• failure to meet required working specification
Describe the pressure terms: • system performance
• pre-charge pressure (p0) and control • pipe-work installations
• working pressure (p1) • layout fastenings
• max. pressure (p2) • leakage prevention

c) Have full knowledge about the fundamental rules of H 3.5.19 Contamination Control
European Pressure Equipment Directive: Describe contamination control methods associ-
• PED ated with:

H 3.5.18 Pipes and Hoses – Installation and • ingression of contamination and the nature of the
Commissioning Procedures contaminant
Describe installation and commissioning procedures • preventative measures to reduce ingression to an
for pipes hoses and seals, and associated selection acceptable level
process and sizing relating to application: • establishing a suitable cleanliness target
• achieving and maintaining a cleanliness target
a) Determine from pipe sizing charts and manu- (ISO and AS standards)
facturers’ catalogues, suitable pipe/hose diameters
• measuring and monitoring cleanliness levels
associated with flow rates, velocities and acceptable
• remedial actions
pressure drops.
• filter types, rating, location and performance
b) Describe the types and application of seals used in
H 3.5.20 Machine Circuitry and Control Features
hydraulic systems, with specific reference to: (Recognition and use of hydraulics and
• static and dynamic seals, electrical symbols)
• cylinder seals Describe and interpret hydraulic circuits and
• pump and motor shaft seals associated methods of control, including failsafe
• seal materials, selection and compatibility methods:
• replacement methods and care to be taken during
installation Recognize and use current graphical hydraulic and
electrical symbols relating to hydraulic systems.
c) State the factors that affect system pressure drop:
• pipe/hose dimensions
• pipe work/manifold block configuration
70

b) List the common faults encountered in hydraulic

H 3.5.21 Installation and Commissioning
systems and associated components and state the
possible causes and effects on system performance:
Procedures
• excessive noise
Describe installation and commissioning
• vibration
procedures to be followed:
• high system/component temperature
• erratic operation
• planning work to be done and listing
• leakage
necessary resources
• pressure too high
• checking component conformance against
technical specification • pressure too low
• following manufacturers’ recommendations • incorrect actuator speed
for installation of a particular component/s • incorrect pump flow rate
• outline commissioning procedures to be followed, • incorrect sequence of operations
taking into consideration: safety/risk assessment, • loads lowering/failure to hold position
operational specification, technical specification, • hose and pipe failure (Section H3.5.18 f)
and start up procedures • contamination level too high
• outline the procedures to be followed to ensure that
system/component/s operates at a satisfactory c) Describe procedures to follow when carrying out
level of performance fault finding, including:
• outline the procedure to be followed to ensure • identifying and determining the nature of the fault
that the work place is re-established ”fit for • planning stages
purpose” • safe working practices to be followed and
• completion of all necessary reports/documentation associated risk assessment
• information necessary to effectively carry out fault
diagnosis and rectification process
H 3.5.22 Maintenance, Monitoring and
• application of FAULT - CAUSE – REMEDY
Fault Finding Procedures
procedures
Describe maintenance, monitoring and fault-
• use of diagnostic equipment and recording
finding procedures:
results
• procedures to follow to rectify problems
a) Outline a maintenance scheme, involving
(adjustments replacements, repair and re-
per- formance and health monitoring, in
commissioning)
terms of:
• establishing system re-start procedures
• maintaining cleanliness standard
• re-establishing work place ”fit for purpose”
• regular use of diagnostic and test equipment
• completion of all necessary reports/documentation
• continuous condition monitoring systems
• analysis of results and actions to be taken
• keeping up to date records and
information systems
• establishing safe working practices and step by
step procedures when dealing with system
breakdowns/component failures/ replacement/ re-
commissioning start up and testing
• leakage detection methods
 71

MOBILE HYDRAULICS & ASSOCIATED CONTROL

PROGRAMME (MH3): RE 2015/06.01 - H
CETOP (Passport) Occupational Level 3
INTRODUCTION METHODOLOGY AND ASSESSMENT

This is a LEVEL 3 Hydraulics Programme, The programme can be offered via a range of
forming the start of a series of competence- learning modes devised by the Approved
based qualifications designed around CETOP Centres but it is envisaged that distance learning
occupational levels. supported by a series of centre based modules
will be the normal system used.
It combines the necessary knowledge and Candidates will be expected to complete a
competence based skills for those people on series of assignments throughout the
route to this high level of qualification, involving programme of study to reinforce the learning
the maintenance and management of both process and attend the programme of center-
Industrial and Mobile hydraulic systems. based modules.
Final assessment for the knowledge­based
units will be by means of a written examination of
CETOP OCCUPATIONAL LEVEL 3 2½ hours duration. These will be prepared and
offered at approved centres or at an engaged
LEVEL (3) This person will be involved in a broad external examination centre. The pass mark for
and often complex range of activities, often the written examination will be 70%.
requiring independent decisions to be made on
technical matters concerning specifications, The expected completion time for a
resources or processes. Planning of work will be competency based programme is one to three
a responsibility, as will the finding and rectifica- years depending on work experience within
tion of faults. Responsibility for the quality of hydraulics and will require a high level of
work undertaken and the required outcomes are personal commitment to study and research the
also included. subjects within the syllabus.

Throughout the programme, emphasis is placed Practical task assessments to verify

upon the development of knowledge relating to competency against the agreed performance
”FUNCTION”, ”OPERATION” and ”APPLICA- criteria will be carried out at the approved
TION”. The knowledge based section will support centre during the education programme period.
the development and effective application of It could be arranged on one to one base or in
practical skills necessary to carry out in a safe groups, candidate/ candidates to tutor.
and effective manner:
All candidates taking a level 3 qualification
• INSTALLATION should have a minimum of 2 years work based
• COMMISSIONING experience involving hydraulics verified by their
• PERFORMANCE TESTING employer.
• PROACTIVE MAINTENANCE AND MACHINE
MANAGEMENT Alternative:
• SERVICING Where candidates do not have 2 years work
• COMPONENT REMOVAL AND REPLACE- based experience they can undertake the
MENT qualification but will not receive the award
until they have completed two years of verified
The development of planning and preparatory employment involving hydraulics.
skills, the use of technical information and
Successful completion of both the knowledge
specifications and the formulation and
based and competency based units will result in
implementation of safe working procedures will
the award of a CETOP Level 3 Mobile
be emphasized throughout all aspects of this
Hydraulics Qualification Certificate. Candidates
programme.
successfully completing only one unit will receive
a CETOP Unit Certificate.

No part of this publication may be photocopied or otherwise reproduced without the prior permission in writing of the Association.
Whilst the Association does its best to ensure that any information that it may give is accurate, no liability or responsibility of any kind is accepted in this respect by the Association,
its members, its servants or agents. Further copies of this document can be obtained from the CETOP, e-mail: [email protected]. PDF-version of this document can be
obtained from the CETOP web-site: www.cetop.org.
72

PRACTICAL TASK ASSESSMENT (MH3)

MH3.3.3 Diagnostics used to locate fault.
Assessment Requirements MH3.3.4 Safe working practices followed at all
In practical tasks, candidates must on at least two times.
occasions, prove their ability to carry out the following: MH 3.3.5 Faulty components replaced.
MH 3.3.6 Cause and effect of faults assessed.
Assessed Ability MH 3.3.7 System re-commissioned in
MH 3.1 Interpret hydraulic circuit diagrams accordance with set procedures.
applicable to a selected machine and MH3.3.8 System operated according
prepare a schematic representation of the to machine specification.
system.
Assessed Ability
Evidence Required MH 3.4 Designated or faulty component
MH3.1.1 Machine function and operating replacement carried out in accordance
principles identified. with given information.
MH3.1.2 Components correctly identified.
MH3.1.3 Function and operation of individual sub- Evidence Required
circuits correctly identified. MH3.4.1 Component checked against technical
MH3.1.4 Machine control inputs and outputs specification.
identified. MH3.4.2 Action plan procedures prepared.
MH3.4.3 Safe working practices determined
and adhered to at all times.
Assessed Ability
MH 3.2 Assemble a hydraulic system from given MH3.4.4 Cleanliness control procedures
information and establish suitable followed at all times.
MH3.4.5 Component removed following
maintenance procedures.
recommended procedures and correct
tools used at all times.
Evidence Required MH3.4.6 Replacement component installed
MH3.2.1 Components selected and conform-
effectively in accordance with
ance checked against system
procedures and respective technical
specification.
data sheets.
MH 3.2.2 Installation plan prepared.
MH3.4.7 Commissioning procedures followed
MH3.2.3 System assembled in a safe and
and adjustments carried out using
efficient manner.
correct instrumentation where
MH3.2.4 Commissioning procedures followed in
necessary.
accordance with technical specification.
MH3.4.8 Start up procedures correctly specified
MH3.2.5 Start up procedures correctly specified and
and followed.
followed.
MH3.4.9 System operated according to
MH3.2.6 System operated according to
specification.
specification.
MH 3.4.10 Work place re-established to required
MH3.2.7 Establish predictive maintenance
levels of tidiness and cleanliness.
procedures to be followed, including:
• component performance testing
Note: Preparation for practical task
• fluid sampling and assessment of
assessment can be a group activity or it
contamination level against target
could be carried out on a ”one to one”
level.
basis between the candidate and the
assessor. Evidence will be obtained by
Assessed Ability
non-intrusive observation, questioning or
MH 3.3 Carry out effective fault diagnosis.
written and verbal reports.
Evidence Required
MH3.3.1 Nature of fault correctly identified.
MH3.3.2 Fault, cause, remedy checklist
prepared.
 73

KNOWLEDGE BASED SECTION (MH3)

MOBILE HYDRAULICS PROGRAMME
(Knowledge Based Section)
CONTENTS

MH3.5.1 Fundamental and Scientific Principles MH3.5.1 Fundamental and Scientific Principles
MH3.5.2 Application of the Fundamental Describe the fundamental principles of power
Principles transmission by hydraulics and associated scientific
MH3.5.3 Hydraulic Fluids principles underlying its use.
MH3.5.4 Valve Mounting Styles/Configurations
MH3.5.5 Control Valves a) List the basic building blocks and describe their
MH 3.5.6 Mobile multifunction Valves function with reference to: prime movers, pumps,
MH 3.5.7 Electrical/Electronic reservoirs, fluids, control valves, filters, coolers, pipe
work and manifold blocks.
Components
MH 3.5.8 Proportional Valve Technology
b) Know the cause and effect of pressure generation,
MH 3.5.9 Hydrostatic Steering Systems
pressure losses, heat generation, fluid leakage,
MH 3.5.10 Pumps and Associated Control
cavitation, aeration, noise and vibration.
Systems
MH 3.5.11 Hydraulic Actuators c) Know the difference between laminar
and turbulent flow and their effect on
(Motors and Cylinders)
system performance.
MH 3.5.12 Closed Hydrostatic Transmissions
MH 3.5.13 Reservoirs, Conditioning and Auxiliary
d) Know the meaning of the term Reynolds
Components
Number and use the associated formula.
MH 3.5.14 Pipes and Hoses - Installation and
Commissioning Procedures
e) Know the difference between static and
MH 3.5.15 Contamination Control
dynamic pressure.
MH 3.5.16 Machine Circuitry and Control
Features (Recognition and use of
symbols) f) Know the quantities and units:
pressure, force, area, displacement, flow rate,
MH 3.5.18 Installation and Commissioning
speed/velocity, torque and power.
Procedures
MH 3.5.19 Maintenance, Monitoring and Fault
Finding Procedures g) Know the formulae relating to:
pressure, force, area, displacement, flow rate,
speed/velocity, torque and power.
KNOWLEDGE BASED UNIT –
h) Know the principles of heat dissipation and
WRITTEN EXAMINATION SPECIFICATION
temperature control:
heat sinks within a system (reservoirs, pipe
The examination paper will contain 8
work and coolers) and effects of ambient
questions integrating the above 16 sections
conditions and working cycle.
• Examination duration will be 2½
i) State and use the relationship between:
consecutive hours
pressure, force and area for cylinders and
• Candidates will be expected to
pressure, torque and displacement per
attempt 5 questions
revolution for pumps and motors.
• Each question will carry equal marks
• Pass mark will be 70%
j) State and use the relationship between:
flow, area and velocity for cylinders, and
Where calculations and formulae are involved, all
flow, displacement per revolution and shaft
progressive stages of the calculation together
speeds for pumps and motors.
with the corresponding units must be shown
k) Know the relationship between:
input and output powers of pumps and motors
and the causes of volumetric and mechanical
inefficiencies.
74

MH3.5.2 Application and Fundamental c) Types of fluids used in mobile machinery:

Principles • hydraulic fluid
Describe the application of the • engine oil
fundamental principles with regard to the: • transmission fluid
• universal oil
a) Relationship between flow rate, • biodegradable fluid
pressure drop, restriction, power • fire-resistant fluid
and heat.
d) ISO/SAE viscosity grades
b) Control of pressure
• pressure generation e) Fluid selection for typical applications (factors
• pressure limiting to be considered):
• pressure unloading • environmental considerations
• pressure reducing • fire resistance
• pressure intensification • toxicity
• water separation
c) Control of flow • filterability
• non-compensated flow control
• pressure compensated flow f) Fluid storage, handling and transfer:
control • explain the need for correct storage, handling, cleanliness
• temperature compensated flow control and transfer systems to be in place and controlled
control by working procedures
• flow dividing • know the requirements associated with COSHH
• regenerative flow regulations
• damping • explain the need for cleanliness control systems to be in
• meter-in, meter-out and by-pass flow control place and associated fluid analysis procedures and
monitoring
d) Control of movement (ISO and AS standards) see section MH3.5.15
• acceleration and deceleration control MH3.5.4 Valve Mounting Styles/ Configurations
• stopping or preventing movement Describe valve mounting styles, standardized
• changing direction interfaces, sizes, flow rates, port layouts and sealing
arrangements, relating to:
MH3.5.3 Hydraulic Fluids • pipe mounting/line mounting
Describe the application and selection of fluids • sub-plate mounting
for use in mobile hydraulic systems relating to: • manifold mounting
• stack, mounting
a) Functions • flange mounted valves
• power transmission • screw in cartridge
• lubrication • slip in cartridge
• cooling • ISO interface valves

b) Characteristics and properties (behavior MH3.5.5 Control Valves

and effect on system performance): Describe the function, operation and application of
• viscosity control valves and interpret their graphical symbols.
• viscosity index
• lubrication a) Flow control devices (fixed and adjustable):
• thermal stability (oxidation) • non-compensated flow control devices (orifices and
• pour point throttle valves)
• remissibility • pressure and temperature compensated flow control
• shear stability valves
• compressibility • hydrostatics
• material compatibility • priority valves
• foaming and aeration resistance • spool flow dividers
• filterability • rotary flow dividers
• fire-resistance • differential lock units
 75

b) Pressure control devices: d) Special features (including inlet, outlet and

• pressure limiting service ports):
• single stage, relief valves • flow sharing (pre and post compensation)
• two stage, pilot operated relief valves • load sensing, pressure limiting and vent control
• unloading valves • load holding
• control features • anti-cavitation
• vent • pressure limiting
• remote control (manual/proportional)
• load sensing e) Valve characteristics:
• pressure reducing • valve sizes, flow rates and associated pressure
• single stage and two stage pressure reducing valves drops
• two way and three way configuration • operating performance (under conditions of
closed, partially open and fully open)
c) Load Holding and Motion Control:
• pilot operated check valves MH3.5.7 Electrical/Electronic Components
• counterbalance with internal and external pilot control Describe the function and application of electrical/
(including the effect of pilot ratios) electronic components
• hose burst control devices
• resistors
d) Direction control devices: • capacitors
• potentiometers
• check valves
• transformers
• pilot operated checks
• diodes
• spool valves
• electronic switches and sensors
• ball valves • pressure
• poppet valves • level
• sequence valves • temperature
(Where appropriate, control features to include simple • flow
on-off and proportional control) • distance
• particle
• water
MH3.5.6 Mobile multifunction Valves • proximity and limit switches
Describe the function, operation, application and • tacho-generator
control features of mobile multifunction control valves • etc.
and interpret their graphical symbols.
MH3.5.8 Proportional Valve Technology
a) Mobile spool direction control valves: Describe the principles of proportional valve
• layout/construction (mono-block/sandwich) technology
• spool configurations (single and multiple)
services • list the potential benefits compared to application
• flow paths - parallel, series and tandem arrange- of lever or “on/off” operated systems
ments including carry-over and alternative inlet • describe the difference in performance of a
sections proportional solenoid to that of a standard
• open center, closed center, single acting, solenoid
double-acting motor half motor, regeneration and float • describe the application of proportional control to
arrangements pressure, flow and direction control describe,
• in block diagram form the control components of a
b) Inlet sections: typical proportional valve electronic amplifier
• pressure control/unloading facilities/priority explain the meaning of the terms: gain
• load sensing connections • adjustment, dead band compensation, ramp
• pilot fluid supply control, dither and pulse width modulation and
demonstrate an understanding of their effects on
c) Controls: system performance explain the recommended
• manual - spring cantered, mechanical hydraulic and practices for
electrical detent • installing proportional electronic control in terms
• solenoid and solenoid pilot of: power supply requirements, enable signals,
• proportional control (with and without spool input signal generation, cable shielding, earthing
position monitoring) and interface with electronic control systems.
• remote control [Joystick], (hydraulic and pneumatic)
• remote control - electrical [Joystick]
76

MH3.5.9 Hydrostatic Steering Systems d) Link to prime mover:

Describe the function, operation and • power take off arrangements
application of hydrostatic steering systems • splitter gearbox
and associated control features: • step up and step down gearbox
arrangements
a) Rotary servo steering units: • belt drives and clutch arrangements
• open centre
• closed centre MH3.5.11Hydraulic Actuators (Motors and
• reaction and non-reaction types Cylinders)
• load sensing systems Describe the function, operation and application
• steer units for electric motor applications of hydraulic actuators, including control features:
• steer units with ‘power beyond’ facilities
• flow amplifiers a) Motors:
• dual displacement steer units • gear
• gerotor/orbit
b) Priority valves:
• vane
• non dynamic types • radial piston
• dynamic types Including variable and dual displacement
control features and associated torque speed
c) Steering systems, modes: characteristics
• single ram single rod, single ram double
• axial piston (swash plate)
rod, double rams single rods
Including variable and dual displacement
• methods of switching between steering modes control features and associated torque speed
characteristics
d) Emergency steering
• bent axis
systems (manual and
Including variable and dual displacement
powered)
control features and associated torque speed
characteristics
• cam/roller types
MH 3.5.10 Pumps and Associated Control
Including variable and dual displacement
Systems
control features and associated torque speed
Describe the function and operation of hydraulic
characteristics
open loop pumps and associated control features:
b) Motor features:
a) Pumps:
• pressure control (pressure compensation)
• external gear
• displacement (torque/speed control)
• internal gear
• parking brake
• vane (fixed and variable)
• dynamic braking (use of counterbalance
• radial piston (fixed and variable) valves)
• axial piston (fixed and variable)
• bent axis piston (fixed and variable) c) Motor performance:
• multiple pumps • series circuitry
• parallel circuitry
b) Know the power - torque relationship
between the prime mover and pump with d) Cylinders, mounting arrangements and
reference to engine speed. construction:
• telescopic
c) Control features: • single acting
• fixed pumps with integral pressure and flow • double acting
control • sealing
• fixed pumps with unloaded valve systems • cushioning
• mechanical/hydraulic servo displacement • mounting arrangements
• Electro-Hydraulic proportional displacement • position monitoring
• pressure compensation/limiting
• load sensing (constant flow/variable speed) e) Semi-rotary actuators:
• torque summation control, including prime • rack and pinion type
mover characteristics • vane type
 77

MH3.5.12 Closed-Loop Hydrostatic • filling connections

Transmissions • sampling points
Describe the function, operation and • level/temperature indication
application of hydraulic components • air and oil filtration
associated with closed loop hydrostatic • pressurized reservoirs
transmission systems: • use of bladder and diaphragms separators
a) Basic configuration:
• close coupled (motor and pump back to b) Describe the use of hydraulic fluid cooling
back units) systems:
• split units (separate motor and pump) single • reservoirs (size, siting and layout)
and double • air blast coolers
• multiple pump/motor layouts • water coolers
• series and parallel operation
c) Describe the function, operation and application of
auxiliary components:
b) Over-centre piston pumps:
• basic construction (axial, bent axis and radial) • bladder type (bag) accumulators
• control methods • piston and diaphragm accumulators
• mechanical • associated safety and control features
• mechanical servo • pressure switches
• pilot pressure
• electronic servo MH3.5.14 Pipes and Hoses – Installation and
• pressure/limitation and displacement control Commissioning Procedures
• automotive control Describe installation and commissioning proce-
dures for pipes hoses and seals, and associated selection
c) Charge pump: process and sizing relating to application:
• construction
• charge pump circuitry a) Determine from pipe sizing charts and manu-
• case flushing (including cooling and facturers’ catalogues, suitable pipe/hose diameters
associated with flow rates, velocities and acceptable
heating functions)
pressure drops.
b) Describe the types and application of seals
d) Control valves: used in hydraulic systems, with specific
• hot oil shuttle valves reference to:
• cross-line relief valves • static and dynamic seals,
• counterbalance valves • cylinder seals
• free-wheel by-pass valves • pump and motor shaft seals
• differential lock valves • seal materials, selection and compatibility
• parking brake systems • replacement methods and care to be taken
dur- ing installation
e) Special control features:
• inch control c) State the factors that affect system pressure
• creep speed drop:
• brake defeat function • pipe/hose dimensions
• hydrostatic braking • pipe work/manifold block configuration
• flow rate
MH3.5.13 Reservoirs, Conditioning
• fluid viscosity and density
and Auxiliary Components • component size/design
Describe the purpose of the system reservoir
and associated fluid conditioning equipment and
d) Hoses types and application:
auxiliary components.
• wire braided
• 2-wire braided
a) Outline a typical system reservoir in terms of: • spiral wire
• size, with reference to oil and air space • thermoplastic
and changes in level
• high temperature and protective sleeved (abra-
• general construction (internal/external), including sion resistant)
return line and port arrangements to minimize
• low temperature
aeration)
78

e) Hose/pipe fitting and assembly procedures: MH 3.5.17 Electronic controls and sensors
• use of adapters and unions, Describe and interpret electronic controls
• use of bite compression fittings and sensor signals including functional safety
• use of ‘O-Ring’ fittings standards:
• use of flange type fittings
• use of formed fittings Recognize different control signals and
• use of welded connections functions that will be used in mobile
machines
f) Hydraulic hose failures relating to: • Types and use of digital BUS systems
• poor installation procedures • Types and use of different control
• failure to meet required working specification signals (analog, digital)
• system performance • Types and use of different sensor signals
• pipe-work installations • Functional Safety standards:
• layout fastenings • Know the requirements aim of IEC and
• leakage prevention EN standards
MH3.5.18 Installation and Commissioning
MH3.5.15 Contamination Control
Procedures
Describe contamination control methods associated
with: Describe installation and commissioning procedures to
• ingression of contamination and the nature of be followed:
the contaminant (particles, water, gasses)
• preventative measures to reduce ingression to • planning work to be done and listing
an acceptable level necessary resources
• establishing a suitable cleanliness target • checking component conformance
• achieving and maintaining a cleanliness target against technical specification
(ISO and AS standards) • following manufacturers’ recommendations
• measuring and monitoring cleanliness levels for installation of a particular component/s
(particles and level of water • outline commissioning procedures to be followed,
ingression/saturation) taking into consideration: safety/risk assessment,
• remedial actions operational specification,
• filter types, rating, location and performance technical specification, and start up procedures
•outline the procedures to be followed to ensure
MH3.5.16 Machine Circuitry and that system/component/s operates at a
Control Features satisfactory level of performance
• outline the procedure to be followed to ensure
(Recognition and Use of Symbols)
that the work place is re-established ”fit for purpose”
Describe and interpret hydraulic circuits and
associated methods of control, including • completion of all necessary
reports/documentation
failsafe methods:
MH3.5.19 Maintenance, Monitoring and Fault
Recognize and use current graphical hydraulic Finding Procedures
and electrical symbols relating to mobile Describe maintenance, monitoring and fault-
hydraulic systems. finding procedures:
Suggested Systems: a) Outline a maintenance scheme, involving per-
• Excavators formance and health monitoring, in terms of:
• Wheeled loader • maintaining cleanliness standard
• Backhoe loaders • regular use of diagnostic and test equipment
• Forklifts • analysis of results and actions to be taken
• Man lifts/access platforms Sweeper • keeping up to date records and information systems
• Telescopic handlers • establishing safe working practices and step by
• Mobile cranes step procedures when dealing with system
• Agricultural tractors breakdowns/component failures/replacement/ re-
• Agricultural harvesters/viners commissioning start up and testing
• leakage detection methods
 79

b) List the common faults encountered in hydraulic c) Describe procedures to follow when
systems and associated components and state carrying out fault finding, including:
the possible causes and effects on system
performance: • identifying and determining the nature of the fault
• excessive noise • planning stages
• vibration • safe working practices to be followed and
• high system/component temperature associated risk assessment
• erratic operation • information necessary to effectively carry out
• leakage fault diagnosis and rectification process
• pressure too high • application of FAULT - CAUSE - REMEDY
• pressure too low procedures
• incorrect actuator speed • use of diagnostic equipment and recording
• incorrect pump flow rate results
• incorrect sequence of operations • procedures to follow to rectify problems
• loads lowering/failure to hold position (adjustments replacements, repair and re-
• hose and pipe failure (Section MH3.5.14(f)) commissioning)
• contamination level too high • establishing system re-start procedures
• re-establishing work place ”fit for purpose”
completion of all necessary reports/document
80

INDUSTRIAL HYDRAULICS & ASSOCIATED

CONTROL PROGRAMME (IH3): RE 2015/06.01 - H
CETOP (Passport) Occupational Level 3

INTRODUCTION METHODOLOGY AND ASSESSMENT

This is a LEVEL 3 Hydraulics Programme, The programme can be offered via a range of
forming the start of a series of competence- learning modes devised by the Approved Centres
based qualifications designed around CETOP but it is envisaged that distance learning supported
occu pational levels. by a series of centre based modules will be the
normal system used.
It combines the necessary knowledge and
competence based skills for those people on Candidates will be expected to complete a series
route to this high level of qualification, involving of assignments throughout the programme of
the maintenance and management of both study to reinforce the learning process and attend
the programme of centre based modules.
Industrial and Mobile hydraulic systems.
Final assessment for the knowledge­based units
CETOP OCCUPATIONAL LEVEL 3 will be by means of a written examination of 2½
hours duration. These will be prepared and
offered at approved centres or at an engaged
LEVEL (3) This person will be involved in a broad external examination centre. The pass mark for
and often complex range of activities, often requir- the written examination will be 70%.
ing independent decisions to be made on technical
matters concerning specifications, resources or The expected completion time for a competency
processes. Planning of work will be a responsi- based programme is one to three years depending
bility, as will the finding and rectification of faults. on work experience within hydraulics and will require
Responsibility for the quality of work undertaken a high level of personal commitment to study and
and the required outcomes are also included. research the subjects within the syllabus.

Throughout the programme, emphasis is placed Practical task assessments to verify competency
upon the development of knowledge relating to against the agreed performance criteria will be
”FUNCTION”, ”OPERATION” and ”APPLICA- carried out at the approved centre during the
TION”. The knowledge based section will support education programme period. It could be
the development and effective application of arranged on one to one base or in groups,
practical skills necessary to carry out in a safe candidate/ candidates to tutor.
and effective manner:
All candidates taking a level 3 qualification should
• INSTALLATION have a minimum of 2 years work based
• COMMISSIONING experience involving hydraulics verified by their
• PERFORMANCE TESTING employer.
• PROACTIVE MAINTENANCE Alternative:
AND MACHINE MANAGEMENT Where candidates do not have 2 years work based
• SERVICING experience they can undertake the qualification but
• COMPONENT REMOVAL will not receive the award until they have
AND REPLACEMENT completed two years of verified employment
involving hydraulics.
The development of planning and preparatory
skills, the use of technical information and Successful completion of both the knowledge
specifications and the formulation and based and competency based units will result in the
implementation of safe working procedures will award of a CETOP Level 3 Industrial Hydraulics
be emphasized throughout all aspects of this Qualification Certificate. Candidates successfully
programme. completing only one unit will receive a CETOP Unit
Certificate.

No part of this publication may be photocopied or otherwise reproduced without the prior permission in writing of the Association.
Whilst the Association does its best to ensure that any information that it may give is accurate, no liability or responsibility of any kind is accepted in this respect by the Association,
its members, its servants or agents. Further copies of this document can be obtained from the CETOP, e-mail: [email protected]. PDF-version of this document can be
obtained from the CETOP web-site: www.cetop.org.
 81

PRACTICAL TASK ASSESSMENT (IH3) Assessed Ability

IH 3.3 Carry out effective fault diagnosis
Assessment Requirements and rectification.
In practical tasks, candidates must on at least
two occasions, prove their ability to carry out Evidence Required
the following: IH 3.3.1 Nature of fault correctly identified.
IH 3.3.2 Fault, cause, remedy checklist prepared.
Assessed Ability IH 3.3.3 Diagnostics used to locate fault ensuring
IH3.1 Interpret hydraulic and Electro-Hydraulic circuit safety at all stages.
diagrams applicable to selected systems IH 3.3.4 Safe working practices followed at all
(against recommended specification) and times.
prepare a schematic representation of the IH 3.3.5 Faulty component replaced, adjusted or
system. repaired in line with planned procedures.
IH 3.3.6 Cause and effect of faults assessed.
Evidence Required IH 3.3.7 System re-commissioned in accordance
IH 3.1.1 Machine function and operating principles with set procedures.
identified. IH 3.3.8 System operated according to machine
IH 3.1.2 Components correctly identified. specification.
IH 3.1.3 Function and operation of individual sub-
circuits correctly identified. Assessed Ability
IH 3.1.4 Machine control inputs and outputs IH3.4 Establish documented procedures and
identified. carry out proactive maintenance and
monitoring of Electro-Hydraulic systems.
Assessed Ability
IH 3.2 Assemble Electro-Hydraulic system involving Evidence Required
on-off control and proportional control from IH 3.4.1 System assessed to determine service/
given information. maintenance schedule requirements.
IH 3.4.2 System assessed to determine routine
Evidence Required monitoring requirements.
IH 3.2.1 Components selected and conformance IH 3.4.3 Documented system established
checked against system specification. including safety requirements/risk
IH 3.2.2 Installation/Action plan prepared. assessment.
IH 3.2.3 System assembled in a safe and efficient IH 3.4.4 Performance testing carried out and
manner. results recorded.
IH 3.2.4 Setting up/commissioning procedures IH 3.4.5 Electrical input and output signals
followed in accordance with technical involving on-off and proportional control
specification. systems checked and recorded.
IH 3.2.5 Start up procedures correctly specified and IH 3.4.6 Fluid sampling carried out and
followed. contamination levels assessed against
IH 3.2.6 System operated according to target cleanliness and result recorded.
specification. IH 3.4.7 Manufacturers recommendations and
IH 3.2.7 Establish proactive maintenance procedures to specifications checked against results.
be followed, including: IH 3.4.8 Safe working practices followed at all
times.
a) component performance testing
Note: Preparation for practical task assessment
b) fluid sampling and assessment can be a group activity or it could be carried
of contamination level against target level out on a ”one to one” basis between the
candidate and the assessor.
c) electrical input and output signals involving
on/off and proportional control systems Evidence will be obtained by non-intrusive
observation, questioning or written and
verbal reports.
82

KNOWLEDGE BASED UNIT (IH3) IH3.5.1 Fundamental and Scientific Principles

Describe the fundamental principles
CONTENTS of power transmission by hydraulics and
associated scientific principles underlying
IH 3.5.1 Fundamental and Scientific Principles their use.
IH 3.5.2 Application of the Fundamental
Principles a) List the basic building blocks and describe their
IH 3.5.3 Hydraulic Fluids function:
IH 3.5.4 Valve Mounting Styles/Configurations prime movers, pumps, reservoirs, fluids, control
IH 3.5.5 Hydraulic System Components valves, filters, coolers, pipe-work
IH 3.5.6 Slip-in Logic Cartridge Valves and manifold blocks.
IH 3.5.7 Fundamental Electrical Principles
IH 3.5.8 Electrical/Electronic Components b) Know the cause and effect of pressure
IH 3.5.9 Proportional Valve Technology generation, pressure losses, heat generation,
IH 3.5.10 Electronic control and sensor signals fluid leakage, cavitation, aeration, noise and
IH 3.5.11 Pumps and Associated Control vibration.
Systems
IH 3.5.12 Hydraulic Actuators c) Know the difference between laminar
(Motors and Cylinders) and turbulent flow, and their effect on
IH 3.5.13 Closed-Loop Hydrostatic system performance.
Transmissions
IH 3.5.14 Reservoirs, Conditioning and Auxiliary d) Know the meaning of the term ‘Reynolds
Components Number’ and use the associated formula.
IH 3.5.15 Pipes and Hoses - Installation and
Commissioning Procedures e) Know the difference between static and
IH 3.5.16 Contamination Control dynamic pressure.
IH 3.5.17 Circuitry and Control Features
(Recognition and use of symbols f) Know the quantities and units: pressure,
hydraulic and electrical) force, area, displacement, flow rate,
IH 3.5.18 Installation and Commissioning speed/velocity, torque and power.
Procedures
IH 3.5.19 Maintenance, Monitoring and Fault g) Know the formulae relating to: pressure,
Finding Procedures force, area, displacement, flow rate,
speed/velocity, torque and power.

KNOWLEDGE BASED UNIT – h) Know the principles of heat dissipation and

WRITTEN EXAMINATION SPECIFICATION temperature control:
• heatsinks within a system
The examination paper will contain 8 (reservoirs, pipe-work and coolers)
questions integrating the above 18 sections. • effects of ambient conditions
and working cycle
• Examination duration will be 2½ consecutive
hours i) State and use the relationship between:
• Candidates will be expected to attempt • pressure, force and area
5 questions • pressure, torque and displacement
• Each question will carry equal marks per revolution for pumps and motors
• Pass mark will be 70%
j) State and use the relationship between:
Where calculations and formulae are involved, all • flow, area and velocity for cylinders
progressive stages of the calculation together with • flow, displacement per revolution and
the corresponding units must be shown. shaft speeds for pumps and motors

k) Know the relationship between:

INDUSTRIAL HYDRAULICS PROGRAMME – • input and output powers of pumps and motors
(Knowledge Based Unit) and the causes of volumetric and mechanical
inefficiencies.
In addition to demonstrating an understanding of
Industrial Hydraulic Systems and Associated
Control, candidates must prove an ability to:
 83

l) List the advantages and disadvantages of • filterability

hydraulic systems compared to: • specific gravity
• mechanical systems • fire-resistance
• electrical systems
• pneumatic systems c) Types of fluids in common use in
industrial applications
IH3.5.2 Application • classifications to ISO standard
of the Fundamental Principles • ISO viscosity grades
Describe the application of the fundamental principles
relating to: d) Fluid selection for typical applications (factors
to be considered)
a) Relationship between flow rate, pressure drop, • environmental considerations
restriction, power and heat. • fire resistance
• toxicity
b) Control of pressure • water separation
• pressure generation • filterability
• pressure limiting
• pressure unloading e) Fluid storage, handling and transfer:
• pressure reducing • explain the need for correct storage, handling,
• pressure intensification cleanliness control and transfer systems to be
in place and controlled by working procedures
c) Control of flow • know the requirements associated with COSHH
• non-compensated flow control regulations
• pressure compensated flow control
• temperature compensated flow control f) Explain the need for cleanliness control
• flow dividing systems to be in place and associated fluid
• regenerative flow analysis procedures and monitoring (ISO
• damping and AS standards)
• meter-in, meter-out and by-pass flow control
IH3.5.4 Valve Mounting Styles/Configurations
d) Control of movement Describe valve mounting styles, standardized
• acceleration and deceleration control interfaces, sizes, flow rates, port-layouts and sealing
• stopping or preventing movement arrangements, relating to:
• changing direction
• pipe/line mounting
• sub-plate mounting
IH3.5.3 Hydraulic Fluids • manifold mounting
Describe the application and selection of fluids for use in • stack, mounting
industrial hydraulic systems relating to: • flange mounted valves
• screw in cartridge
a) Functions: • slip in cartridge
• power transmission • ISO interface valves
• lubrication
• cooling IH3.5.5 Hydraulic System Components
Describe the function, operation and application of
b) Characteristics and properties control valves and interpret their graphical symbols
(behavior and effect on system performance): (control features to include mechanical, solenoid and
• viscosity solenoid pilot).
• viscosity index
• lubricity a) Flow control devices: (fixed and adjustable)
• thermal stability (oxidation) • non-compensated flow control devices (orifices
• pour point and throttle valves)
• demulsibility • pressure and temperature compensated
• shear stability flow control valves
• compressibility • hydrostats and application with proportional
• material compatibility control valves
• foaming and aeration resistance
84

• spool flow dividers • meaning of the terms amplitude, frequency,

• rotary flow dividers periodic time and RMS
• define the terms digital and analogue associated
b) Pressure control devices: with control systems
• pressure limiting • describe the fundamental principles of open
• single stage, relief valves and closed loop control
• two stage, pilot operated relief valves
• unloading valves IH3.5.8 Electrical/Electronic Components
• control features Describe the function and application of
• vent electrical/electronic components
• remote control
• load sensing • resistors
• pressure sensing (application of • capacitors
pressure switches) • potentiometers
• pressure reducing • transformers
• single stage and two stage pressure • diodes
reducing valves with relieving function • electronic switches and sensors
• pressure
c) Load Holding and Motion Control: • level
• pilot operated check valves • temperature
• counterbalance with internal and external pilot • flow
control (including the effect of pilot ratios) • distance
• particle
d) Direction control devices: • water
• check valves • proximity and limit switches
• pilot operated check • tacho-generator
• etc.
• spool valves
• ball valves
IH3.5.9 Proportional Valve Technology
• poppet valves
Describe the principles of proportional valve
• sequence valves
technology
e) control features to include – on-off and
• list the potential benefits compared to
proportional control application of "on/off" operated systems
• describe the difference in performance of a
IH3.5.6 Slip-in Logic Cartridge Valves
proportional solenoid to that of a standard
Describe the function, operation and application
solenoid
Slip-in (logic) cartridge elements
• describe the application of proportional control to
pressure, flow and direction control
• construction and manifold assembly
(including feedback and non-feedback valves,
• sizes and associated flow rates
direct and two stage versions)
• operating principles
• describe, in block diagram form the control
• application for pressure, flow and direction
components of a typical proportional valve
control including associated control methods
electronic amplifier
• explain the meaning of the terms: gain
IH3.5.7 Fundamental Electrical Principles
adjustment, dead band compensation, ramp
Describe the fundamental principles and control,
control, dither and pulse width modulation and
applicable to the use and application of electrical/
demonstrate an understanding of their effects
electronic technology.
on system performance
• explain the recommended practices for installing
• state and use the relationship between voltage,
proportional electronic control in terms of: power
current, resistance and power
supply requirements, enable signals, input signal
• state the relationship between movement,
generation, cable shielding, earthing and
magnetism and current
interface with PLC’s
• meaning of the term inductance and its effect
upon DC circuits
• meaning of the term capacitance and its effect
upon DC circuits
 85

d) Cylinders, mounting arrangements and

IH 3.5.10 Electronic control and sensor construction:
signals • single acting
Describe and interpret electronic controls and • double acting
sensor signals including functional safety • through rod
standards: • sealing
• cushioning
Recognize different control signals and functions • mounting arrangements
that will be used in industrial machines. • position monitoring
• Types and use of digital BUS systems e) Semi-rotary actuators:
• Types and use of different control signals • fixed pumps with relief valve and
(analog, digital) unloading systems
• Types and use of different sensor signals • rack and pinion type
• Functional Safety standards: • vane type
Know the requirements aim of IEC and EN • mechanical/hydraulic servo displacement
standards • Electro-Hydraulic proportional displacement
• pressure compensation with and without remote pressure
control
• load sensing
IH 3.5.11 Pumps and Associated Control
• constant power
Systems
Describe the function and operation of c) Relationship between pressure and flow (Q/P) characteristics
hydraulic pumps and associated control features:
a) Pumps:
• external gear IH 3.5.12 Hydraulic Actuators (Motors and Cylinders)
• internal gear Describe the function, operation and application
• vane (fixed and variable) of hydraulic actuators, including control features:
• radial piston (fixed and variable)
• axial piston (fixed and variable) a) Motors:
• bent axis piston (fixed and variable) • gear
• multiple pumps • gerotor/orbit
• vane
b) Control features: • radial piston
• axial piston (swash plate) Including variable and dual displacement control features and
Including variable and dual displacement control associated torque speed character- istics
features and associated torque speed character-
istics
• bent axis IH 3.5.13 Close-Loop Hydrostatic Transmissions
Including variable and dual displacement control Describe the function, operation and application of
features and associated torque speed hydraulic components associated with closed loop
characteristics hydrostatic transmission systems:
• cam/roller types
Including variable and dual displacement control a) Basic configuration:
features and associated torque speed • pump and motor layout and associated control
characteristics elements

b) Motor features: b) Over-centre piston pumps:

• pressure control (pressure compensation) • basic construction (axial, bent axis and radial)
• displacement (torque/speed control) • control methods
• parking brake • mechanical
• dynamic braking (use of counterbalance valves) • mechanical servo
• pilot pressure
c) Motor performance: • electronic servo
• series circuitry • pressure/limitation and displacement control
• parallel circuitry
86

c) Charge pump: b) Describe the types and application of

• construction seals used in hydraulic systems, with
• charge pump circuitry specific reference to:
• case flushing (including cooling and • static and dynamic seals
heating functions) • cylinder seals
• pump and motor shaft seals
d) Control valves: • seal materials, selection and compatibility
• hot oil shuttle valves • replacement methods and care to be taken
• cross-line relief valves during installation
• counterbalance valves
• free-wheel by-pass valves c) State the factors that affect system pressure
drop:
• pipe/hose dimensions
IH 3.5.14 Reservoirs, Conditioning • pipe work/manifold block configuration
and Auxiliary Components • flow rate
Describe the purpose of the system reservoir • fluid viscosity and density
and associated fluid conditioning equipment • component size/design
and auxiliary components.
d) Hoses types and application:
a) Outline a typical system reservoir in terms of: • wire braided
• size, with reference to oil and air space • 2-wire braided
and changes in level • spiral wire
• general construction (internal/external), including • thermoplastic
return line and port arrangements to minimise • high temperature and protective
aeration sleeved (abrasion resistant)
• filling connections • low temperature
• sampling points
• level/temperature indication e) Hose/pipe fitting and assembly procedures:
• air and oil filtration • use of adapters and unions
• pressurized reservoirs • use of bite compression fittings
• use of bladder and diaphragm separators • use of ‘O-ring’ fittings
• use of flange type fittings
b) Describe the use of hydraulic fluid • use of formed fittings
cooling systems: • use of welded connections
• reservoirs (size, siting and layout)
• air blast coolers f) Hydraulic hose failures relating to:
• water coolers • poor installation procedures
• failure to meet required working specification
c) Describe the function, operation • system performance
and application of auxiliary components: • pipe-work installations
• bladder type (bag) accumulators • layout fastenings leakage prevention
• piston and diaphragm accumulators
• associated safety and control features
• pressure switches IH3.5.16 Contamination Control
Describe Contamination Control Methods associated with:

IH 3.5.15 Pipes and Hoses – Installation and • ingression of contamination and the nature of the
Commissioning Procedures contaminant particles, water, gasses)
Describe installation and commissioning procedures • preventative measures to reduce ingression to an
for pipes, hoses and seals, and associated selection acceptable level
process and sizing relating to application: • establishing a suitable cleanliness target,
• achieving and maintaining a cleanliness target (ISO and
a) Determine from pipe sizing charts and AS standards)
manufacturers’ catalogues, suitable pipe/hose • measuring and monitoring cleanliness levels (particles
diameters associated with flow rates, and level of water ingression/saturation)
velocities and acceptable pressure drops. • remedial actions
• filter types, rating, location and performance
 87

IH 3.5.17 Circuitry and Control Features

(Recognition and use of symbols – hydraulic
and electrical)
b) List the common faults encountered in
Describe and interpret hydraulic circuits and
hydraulic systems and associated components
associated methods of control, including fail safe
and state the possible causes and effects on
methods:
system performance relating to:
• excessive noise
• Recognize and use current graphical hydraulic and
• vibration
electrical symbols
• system temperature/component
temperature high
IH 3.5.18 Installation and Commissioning
• erratic operation
Procedures
• leakage
Describe installation and commissioning procedures
• pressure too high
to be followed:
• pressure too low
• incorrect actuator speed
• planning work to be done and listing necessary
• incorrect pump flow rate
resources
• incorrect sequence of operations
• checking component conformance
• loads lowering/failure to hold position
against technical specification
• hose and pipe failure (Section IH3.5.15(f))
• following manufacturers’ recommendations for
• contamination level too high
installation of a particular component(s)
•outline commissioning procedures to be fol- lowed,
c) Describe procedures to follow when
taking into consideration: safety/risk assessment,
carrying out fault finding, in terms of:
operational specification, technical specification and
• identifying and determining the nature of the fault
start up procedures
• planning stages
• safe working practices to be followed and
• outline the procedures to be followed to ensure that associated risk assessment
system/component(s) operates at a satisfactory level • information necessary to effectively carry out
of performance fault diagnosis and rectification process
• outline the procedure to be followed to ensure that • application of FAULT - CAUSE – REMEDY
the work place is re-established ”fit for purpose” procedures
• completion of all necessary • use of diagnostic equipment and recording
reports/documentation results
IH 3.5.19 Maintenance, Monitoring and Fault • procedures to follow to rectify problems (adjust-
Finding Procedures ments, replacements, repair and re-
Describe maintenance, monitoring and fault commissioning)
finding procedures: • establishing system re-start procedures
• re-establishing work place - ”fit for purpose”
a) Outline a maintenance scheme, involving • completion of all necessary
performance and health monitoring, in terms of: reports/documentation
• maintaining cleanliness standard
• regular use of diagnostic and test equipment
• analysis of results and actions to be taken
(prognosis)
• keeping up to date records and information
systems
• establishing safe working practices and step by
step procedures when dealing with system
breakdowns/component failures/replacement/
re-commissioning start up and testing
• leakage detection methods
EDUCATION
RECOMMENDATIONS

PNEUMATICS PROGRAMMES

PNEUMATICS PROGRAMME (P1):

RE 2015/06.01 – P
CETOP (Passport) Occupational Level 1

PNEUMATICS PROGRAMME (P2):

RE 2015/06.01 – P
CETOP (Passport) Occupational Level 2

PNEUMATICS & CONTROL PROGRAMME (P3):

RE 2015/06.01 – P
CETOP (Passport) Occupational Level 3

No part of this publication may be photocopied or otherwise reproduced with-

out the prior permission in writing of the Association. Whilst the Association
does its best to ensure that any information that it may give is accurate, no
liability or responsibility of any kind is accepted in this respect by the Associa-
tion, its members, its servants or agents.
 89

FOREWORD

These Competence Based Qualifications have The level 3 programmes place emphasis on
been developed by CETOP to meet the complex systems, integrated operations and
occupational levels of those people involved in the their associated controls including the electrical /
maintenance and management of fluid power electronic interface. They involve technical
systems and cover the specific subjects of power specifications and the development of greater
pneumatics and associated control systems. They in-depth knowledge associated with component
form a structure for progressive learning and the characteristics, system performance and inter-
acquisition of a range of competence assessed pretation.
skills. They have now been accepted by CETOP
as industry standard qualifications forming part the Each level involves calculations and the use of
harmonisation programme and the proposed formulae, emphasis is also placed upon the
passport for Europe within this sector of ability to read and interpret circuit diagrams. The
engineering. development of diagnostic skills and the ability
to act accordingly is involved at every level
Relating to CETOP Occupational Levels thereby applying a fault-cause-remedy approach
throughout.
Level 3
Where the same subjects appear at more
•Pneumatics & Control (P3) than one level they are dealt with at the
appropriate depth and in a manner that meets
the requirements of that level.
Level 2
It is advisable in all cases to study the content of
Pneumatics (P2) the previous levels before taking a higher level.
This will ensure that your prior theoretical know
ledge and application experience is sufficient for
you to proceed. You should seek advice from your
Level 1
nearest Approved Centre and if in doubt arrange
•Pneumatics (P1) a formal meeting with a tutor to carry out an
analysis to identify your strengths and weakness
and jointly establish a plan for your progression.

For further details of these industry standard

Each level can be considered as a stand-alone qualifications and Approved Centres visit the
qualification and level of achievement. However, web-site: www.cetop.org
each level progresses to a higher level of
knowledge, understanding and application. Developed on behalf of the CETOP Education
In all cases candidates should ensure that they Commission, representatives from CETOP mem-
have the appropriate knowledge and experience ber Associations, this programme represents one
to commence the qualification level chosen. Level of a range of new competence based
1 programmes provide a foundation of knowledge qualifications recommended by CETOP.
with emphasis placed upon fundamen-tal It is intended for those personnel involved in the
principles, component functionality, operation and maintenance and management of pneumatic
recognition together with an understanding of fluid systems who require knowledge and competence
power systems at a basic level. based skills to support work based activities such
The level 2 programmes ensure component as: planning and preparation, interpreting and
functionality, operation and application are fully using technical information, devising and follow-
understood. These programmes have a higher ing sound procedures associated with
technical content than the level 1 programmes installation, commissioning, testing, fault
and provide a more in-depth approach to function, diagnosis, rectification, maintenance, servicing
operation, application and the interpretation of and re-establishing a machine "fit for purpose".
circuitry.
90

PNEUMATICS PROGRAMME (P1):

RE 2015/06.01 - P
CETOP (Passport) Occupational Level 1
INTRODUCTION • INSTALLATION
• COMMISSIONING
This is the LEVEL 1 Pneumatics Programme, • PERFORMANCE TESTING
forming the start of a series of competence- • PREDICTIVE MAINTENANCE
based qualifications designed around CETOP AND MACHINE MANAGEMENT
occupational levels. • SERVICING
• COMPONENT REMOVAL
It combines the necessary knowledge and AND REPLACEMENT
competence based skills for those people on
route to a higher level qualification at levels 2 and The development of Planning and Preparatory Skills,
3, involving the maintenance and management of the use of technical information and specifications and
Pneumatic systems. the formulation and implementation of safe working
procedures will be emphasized throughout all aspects
Note: In all cases, each programme of this programme.
represents a ”stand-alone” qualification but
can also be a progressive route to a higher
level. METHODOLOGY AND ASSESSMENT

The programme can be offered via a range of

CETOP OCCUPATIONAL LEVEL 1 learning modes devised by the Approved Centres
but it is envisaged that distance learning support-
LEVEL (1) This person will perform activities that ed by a series of centre-based modules will be
follow an established procedure. Activities will be the normal system used.
recurring and of a short-term nature. The reaction
to most problems will be to summon help or Candidates will be expected to complete a se-
follow a predefined set of actions. ries of assignments throughout the programme
of study to reinforce the learning process and
This level 1 programme provides an excellent attend the programme of centre-based modules.
introduction to power pneumatics and places
great emphasis on the understanding of Final assessment for the knowledge-- based units
fundamental principles, component functionality will be by means of a written examination of 2
and principles of operation. hours duration. These will be prepared and offered
at approved centres or at an engaged external
Emphasis upon health and safety and that examination centre. The pass mark for the written
of developing safe working practices is applied examination will be 60%.
throughout, as a CORE ELEMENT within the
scheme. CORE ELEMENTS are not necessarily The expected completion time for this competence
taught as specific subject areas but integrated based programme is 1 - 2 years and will require a
within the scheme. high level of personal commitment to study and
research the subjects within the syllabus.
Throughout the programme, emphasis will
be placed upon the development of Practical task preparation and competence
knowledge relating to ”FUNCTION”, based unit assessment will be carried out by
”OPERATION” and ”APPLICATION”. arrangement with the Approved Centre during
the year. Final assessment will be carried out on
The knowledge-based section will support the a ”one to one” basis or in groups, candidate to
development and effective application of tutor, and the outcome will be pass or fail.
Practical Skills necessary to carry out in a
safe and effective manner that of: Successful completion of both the knowledge
based and competence based units will result in
No part of this publication may be photocopied or otherwise reproduced without the prior permission in writing of the Association.
Whilst the Association does its best to ensure that any information that it may give is accurate, no liability or responsibility of any kind is accepted in this respect by the Association,
its members, its servants or agents. Further copies of this document can be obtained from the CETOP, e-mail: [email protected]. PDF-version of this document can be
obtained from the CETOP web-site: www.cetop.org.
 91

the award of a CETOP Level 1 Pneumatics KNOWLEDGE BASED UNIT (P1) CONTENTS
Qualification Certificate (P1). Candidates
successfully completing only one unit will P 1.4.1 Fundamental Scientific Principles.
receive a CETOP Unit Certificate. P 1.4.2 Application of Fundamental Principles.
P 1.4.3 Compressed Air Installations.
P1.4.4 Legal Regulations (The Pressure Sys-
PRACTICAL TASK ASSESSMENT (P1) tems Safety Regulations, PED).
P 1.4.5 Airline Components.
Assessment Requirements P 1.4.6 Pneumatic and Electro-Pneumatic Cir-
In practical tasks, candidates must on at least cuit Components.
two occasions, prove their ability to carry out P 1.4.7 Circuit and Control Features (Recogni- tion
the following: and use of pneumatic and electrical
component symbols).
Assessed Ability P 1.4.8 Basic Maintenance procedures.
P 1.1 Interpret pneumatic circuit diagrams.
KNOWLEDGE BASED UNIT –
Evidence Required WRITTEN EXAMINATION SPECIFICATION
P 1.1.1 Components correctly identified.
P 1.1.2 Application of components identified. The examination paper will contain questions from
P 1.1.3 Operation of pneumatic system relating to 8 sections of the programme.
control input and machine output identified.
• Examination with a minimum duration 2
Assessed Ability consecutive hours
P 1.2 Design pneumatic systems from given • Pass mark will be 60%
information. • Question style may be single subject, multiple
subject, short answer and multiple choice
Evidence Required
P1.2.1 Appropriate components selected and adjusted Where calculations and formulae are involved, all
as necessary. progressive stages of the calculation together with
P1.2.2 System assembled in a safe and efficient manner. the corresponding units must be shown.
P1.2.3 Start up and commissioning procedures correctly
specified and followed. PNEUMATICS - (Knowledge Based Unit)
P1.2.4 System operates according to
requirements. P1.4.1 Fundamental Scientific Principles
P1.2.5 Safe working practice and statutory Describe the fundamental principles of power
regulations followed at all times. transmission by pneumatics and associated
scientific principles underlying their use.
Assessed Ability
P 1.3 Carry out routine maintenance on a) List the basic components and describe their
pneumatic systems. function
• prime movers, compressor, coolers, air receiver,
Evidence Required dryers and pipe-work
P1.3.1 Service/maintenance requirements, establish
schedule. b) Know the quantities and units
P1.3.2 Service/maintenance undertaken as per • pressure, force, area, air consumption, flow
schedule, in safe and efficient manner. rate, speed/velocity, torque and power
P1.3.3 Faulty component, replaced, adjusted or
repaired in line with planned procedures. c) State and use the relationship between:
P1.3.4 System tested after maintenance to ensure • pressure, force and area
efficient working.
P1.3.5 Safe working practice and statutory d) List the advantages and disadvantages of
regulations followed at all times. pneumatic systems compared to:
• mechanical systems
• electrical systems
• hydraulic systems

e) State and use the relationship between voltage,

current, resistance and power
92

P1.4.2 Application of the P1.4.3 Compressed Air Installations

Fundamental Principles Describe compressed air installations:
Describe the application of the
fundamental principles relating to: a) Draw a typical compressed air installation system block
diagram showing the relative position of the following
a) Relationship between flow rate, components:
pressure drop, pipe size and length • compressors
• coolers
b) Control of Pressure • air receiver
• distinguish between gauge pressure • dryers
and absolute pressure • filters
• compression ratio • water traps
• pressure relief • service units
• pressure reduction
P1.4.5 Airline Components b) State the function of the components listed in a)
State the function of the airline components: above

a) shut off valve P1.4.4 Legal Regulations (The Pressure Systems

Safety Regulations)
b) filter State the legal regulations for pressure systems (The
Pressure Systems Safety Regulations)
c) pressure regulator and gauge
applications of the following types of cylinder
d) soft start/dump valve A) single acting
B) double acting
e) lubricator • state the reason for cushioning in double acting
cylinders
P1.4.6 Pneumatic and
Electro-Pneumatic b) control valves
Circuit Components • identify the need in a circuit for directional
Describe pneumatic and Electro- control and flow regulation valves
Pneumatic circuit components: • identify the main features of 2/2, 3/2, 4/2, 5/2
spool and poppet valves
a) air cylinders, motors and semi-rotary • identify the different methods of valve actuation
actuators A) manual
• state that air cylinders and motors B) mechanical
convert fluid energy into work C) electrical
D) pneumatic
c) Control of flow • state the principle and purpose of silencers
• directional and reclassifiers
• describe how speed can be adjusted using
control valves c) pipe-work and connectors
• identify the main features and state typical • distinguish between rigid and flexible pipe-work
flow • identify couplings and connectors for use with
• soft start/dump above pipe-work
• flow control, bi-directional
• flow control with by-pass d) state the function of the listed components
• non-return • solenoids
• types of solenoid
d) Control of movement • switching (‘ac’ and ‘dc’)
• speed • direct acting
• stopping or preventing movement • solenoid-pilot operated
• changing direction • manual override
• reed switches
• proximity sensors
 93

P1.4.7 Circuit and Control Features • establishing safe working practices and
(Recognition and use of Pneumatic and step by step procedures when dealing with
Electrical Component Symbols) system breakdowns/component
Describe and prepare listed pneumatic circuits and failures/replacement/ re-commissioning
associated methods of control. start up and testing

a) recognize and use ISO graphical b) Checks for common faults

symbols for listed components encountered in Pneumatic systems
• filter and associated components:
• pressure regulator and gauge • check air supply pressure
• lubricator indicated on pressure gauge
• single acting cylinder • check contamination level in filter bowl
• double acting cylinder • check oil level in lubricator (if fitted)
• 2/2, 3/2, 4/2, 5/2 directional control valves • check positional sensors
• flow control valves • check speed control settings

b) sketch single cylinder circuit diagrams to c) Describe procedures to follow

control piston movements when carrying out fault finding, in
• manual operation of single acting cylinder terms of:
• manual operation of double acting cylinder • identifying and determining the nature of the
• manual operation of double acting cylinder fault
with speed control • planning stages
• safe working practices to be followed and
c) recognize the numerical system ISO standard asso- ciated risk assessment
• information necessary to effectively carry
d) recognize and use IEC graphical symbols out fault diagnosis and rectification
process
• application of FAULT-CAUSE-
P1.4.8 Basic Maintenance Procedures REMEDY procedures
Describe maintenance, monitoring and fault- finding • use of diagnostic equipment and
procedures: recording results
• procedures to follow to rectify
a) Outline the maintenance scheme, involving problems (adjustments,
performance and health monitoring in terms of: replacements, repair and re-
• maintaining cleanliness standard commissioning)
• regular use of diagnostic and test equipment • establishing system re-start procedures
• analysis of results and actions to be taken • re-establish work place- ‘fit for purpose’
(prognosis) • completion of all necessary
reports/ documentation
• keeping up to date records and information
systems
94

PNEUMATICS PROGRAMME (P2):

RE 2015/06.01 - P
CETOP (Passport) Occupational Level 2

INTRODUCTION
The development of Planning and Preparatory
This is a LEVEL 2 Pneumatics (P2) Programme, Skills, the use of technical information and
forming the start of a series of competence- specifications and the formulation and
based qualifications designed around CETOP implementation of safe working procedures will
occupational levels. be emphasized throughout all aspects of this
programme.
It combines the necessary knowledge and
competence based skills for those people on route to
a higher level qualification at level 3, involving the METHODOLOGY AND ASSESSMENT
maintenance and management of pneumatic
systems. The programme can be offered via a range of
learning modes devised by the Approved
Note: In all cases, each programme represents a Centres but it is envisaged that distance
”stand-alone” qualification but can also be a learning support- ed by a series of centre-based
progressive route to a higher level. modules will be the normal system used.

Candidates will be expected to complete a

CETOP OCCUPATIONAL LEVELS series of assignments throughout the
programme of study to reinforce the learning
LEVEL (2) This person will perform a variety of process and
activities needing some understanding of the tech- attend the programme of centre-based modules.
nical factors involved. The activities may require the
interpretation and application of varied and non- Final assessment for the knowledge-- based
routine specifications. Activities will involve the use of units will be by means of a written examination
simple diagnostic checks and ability to make a of 2 hours duration. These will be prepared and
positive response to deviations. Co-operation with offered at approved centres or at an engaged
others in team or work groups may be required. external examination centre. The pass mark for
the written examination will be 60%.
Throughout the programme, emphasis will be
placed upon the development of knowledge The expected completion time for this
relating to ”FUNCTION”, ”OPERATION” and competence based programme is 1–2 years
”APPLICATION”. and
will require a high level of personal commitment
The knowledge-based section will support the to study and research the subjects within the
development and effective application of Practical syllabus.
Skills necessary to carry out in a safe and effective Practical task preparation and competence
manner that of: based unit assessment will be carried out by
arrangement with the approved centre during
• INSTALLATION the year. Final assessment will be carried out
• COMMISSIONING on a ”one to one” basis or in groups, candidate
• PERFORMANCE TESTING to tutor, and the outcome will be pass or fail.
• PREDICTIVE MAINTENANCE AND
MACHINE MANAGEMENT Successful completion of both the knowledge
• SERVICING based and competence based units will result in
• COMPONENT REMOVAL AND the award of a CETOP Level 2 Pneumatics
EPLACEMENT Qualification Certificate (P2). Candidates
successfully completing only one unit will
receive a CETOP Unit Certificate.
No part of this publication may be photocopied or otherwise reproduced without the prior permission in writing of the Association.
Whilst the Association does its best to ensure that any information that it may give is accurate, no liability or responsibility of any kind is accepted in this respect by the Association,
its members, its servants or agents. Further copies of this document can be obtained from the CETOP, e-mail: [email protected]. PDF-version of this document can be
obtained from the CETOP web-site: www.cetop.org.
 95

PRACTICAL TASK ASSESSMENT (P2)

Assessed Ability
Assessment Requirements P 2.4 Carry out routine maintenance on pneumatic/Electro-
In practical tasks, candidates must on at least Pneumatic systems.
two occasions, prove their ability to carry out
the following: Evidence Required
P 2.4.1 Service/maintenance requirements, establish
Assessed Ability schedule.
P 2.1 Interpret pneumatic/Electro- Pneumatic P 2.4.2 Service/maintenance undertaken as
circuit diagrams. per schedule, in safe and efficient manner.
P 2.4.3 Faulty component, replaced, adjusted or repaired in
P2.1.1 Components correctly identified. line with planned procedures.
P2.1.2 Application of components identified. P 2.4.4 System tested after maintenance to
P2.1.3 Operation of pneumatic/Electro- ensure efficient working.
Pneumatic system relating to control input P 2.4.5 Safe working practice and statutory
and machines output identified. regulations followed at all times.

Assessed Ability
P 2.2 Design pneumatic/Electro-Pneumatic KNOWLEDGE BASED UNIT (P2)
systems from given information.
CONTENTS
Evidence Required
P 2.2.1 Appropriate components selected and P 2.5.1 Fundamental and Scientific Principles.
adjusted as necessary. P 2.5.2 Application of Fundamental Principles.
P 2.2.2 System assembled in safe and efficient. P 2.5.3 Compressed Air Installations. P2.5.4 Legal
P 2.2.3 Start-up and commissioning procedures Regulations (The Pressure
correctly specified and followed. Systems Safety Regulations).
P 2.2.4 System operates according to P 2.5.5 Pneumatic Circuit Components.
requirements. P 2.5.6 Fundamental Electrical Principles.
P 2.2.5 Safe working practice and statutory P 2.5.7 Electro-Pneumatic Circuit Components.
regulations followed at all times. P 2.5.8 Hydro-Pneumatic Components.
P 2.5.9 Pipe-work and Connectors.
Assessed Ability P 2.5.10 Seals.
P 2.3 Identify and rectify faults in pneumatic/ P 2.5.11 Circuit and Control Features (Recognition
Electro-Pneumatic systems. and use of pneumatic and electrical
component symbols).
Evidence Required P 2.5.12 Emergency Fail-safe and Safety Systems.
P 2.3.1 Nature of faults correctly identified.
P 2.5.13 Installation and Commissioning Procedures.
P 2.3.2 Fault finding check list prepared.
P 2.5.14 Maintenance, Monitoring and Fault Finding
P 2.3.3 Diagnostics used to locate fault,
Procedures.
ensuring safety at all stages.
P 2.3.4 Machine/system shut down safely in
KNOWLEDGE BASED UNIT –
correct sequence as necessary.
WRITTEN EXAMINATION SPECIFICATION
P 2.3.5 Faulty component repaired/replaced/
adjusted as necessary.
The examination paper will contain 8 questions from
P 2.3.6 Cause and effect of faults accurately
the 14 sections.
assessed.
P 2.3.7 Machine/system re-commissioned in
• Examination duration of a minimum of 2
accordance with set procedures.
consecutive hours
P 2.3.8 Machine/system operates according to
• Candidates will be expected to attempt 5
requirements.
questions
P 2.3.9 Safe working practice and statutory
• Each question will have equal weighting (20%)
regulations followed at all times.
• Questions may be single subject or integrated
• Pass mark will be 60%
96

Where calculations and formulae are involved, d) Control of movement

all progressive stages of the calculation together • speed
with the corresponding units must be shown. • stopping or preventing movement
• changing direction

PNEUMATICS - (Knowledge Based Unit) P2.5.3 Compressed Air Installations

Describe compressed air installations.
P2.5.1 Fundamental and Scientific Principles
Describe the fundamental principles of power a) draw a typical compressed air installation
transmission by pneumatics and associated system block diagram showing the relative
scientific principles underlying their use. position of the following components:
• compressors
a) List the basic components and describe • coolers
their function: • air receiver
• prime movers, compressor, coolers, air • relief valves
receiver, dryers and pipe-work • dryers
• filters
b) Know the quantities and units: • water traps
• pressure, force, area, air consumption, • service units
flow rate, speed/velocity, torque and
power b) state the function of the components
listed in a) above
c) Know the formulae relating to:
• pressure, force, area, air consumption, c) describe air compressor systems:
flow rate, speed/velocity, torque and • list air compressor types in common use: re-
power ciprocating, rotary and axial types – single and
multistage
d) State and use the relationship between: • list the factors influencing the choice of compres-
• pressure, force and area sor type for a particular compressed air installa-
tion
e) List the advantages and disadvantages
of pneumatic systems compared to: d) describe the need for drying compressed air
• mechanical systems • the purpose of drying
• electrical systems • differences in principle of absorption, absorption
• hydraulic systems and low temperature drying methods

P2.5.2 Application e)describe the layout and installation of pipe-work

of the Fundamental Principles for main line systems
Describe the application of the fundamental • state the requirements for pipeline gradient (fall)
principles relating to: and method of support
• distinguish between dead-end and ring main
a) Relationship between flow rate, systems, state the advantages of each system
pressure drop, pipe size and length • sketch typical methods of tapping air lines for
power supplies and for draining
b) Control of Pressure
• distinguish between gauge pressure f) state the function of the airline components
and absolute pressure • shut off valve
• compression ratio • soft start/dump valve
• pressure relief • filter
• pressure reduction • pressure regulator
• pressure gauge
c) Control of Flow • lubricator
• directional
• soft start/dump P 2 . 5 . 4 Legal Regulations (The Pressure
• flow control, bi-directional Systems Safety Regulations)
• flow control with by-pass State the legal regulations for pressure
• non-return systems (The Pressure Systems Safety
Regulations, PED)
 97

P2.5.5 Pneumatic Circuit Components • conventional valves

Describe pneumatic circuit components. • moving part logic valves
• state the principle and purpose of silencers and
a) air cylinders, motors and semi-rotary actuators reclassifiers
• state that air cylinders and motors convert • state the functions of a reservoir in the circuit
fluid energy into work • state the function of ‘blocking’ and ‘unloading’
• calculate the static force developed by an air valves
cylinder, state the effect of the piston rod on the
force developed P2.5.6 Fundamental Electrical Principles
• state the need to increase theoretical static force Describe the fundamental principles and control,
by a minimum of 30% for dynamic applications applicable to the use and application of
• list the factors that affect piston speed electrical/electronic technology:
• state the difficulties associated with slow speed
control of an air cylinder • state and use the relationship between voltage,
• identify the main features and state typical current value, resistance and power
applications of the following types of cylinder • state the relationship between movement,
• single-acting magnetism and current
• double-acting • meaning of the term inductance and its effect
• diaphragm upon DC circuits
• rod-less • meaning of the term capacitance and its effect
• non-rotating upon DC circuits
• state the main reasons for the following special • meaning of the terms amplitude, frequency,
features in cylinders periodic time and RMS
• cushioning • define the terms digital and analogue associated with
• magnetic piston control systems
• piston rod locking mechanisms • describe the fundamental principles of open and
• piston rod guidance and anti-rotation closed loop control
• identify the main features and state typical
applications of rotary air motors and semi-rotary P2.5.7 Electro-Pneumatic Components
actuators
a) state the function of the listed components
b) vacuum components • solenoids
• vacuum generators • types of solenoid
• suction cups • switching (‘ac’ and ‘dc’)
• holding valves • direct acting
• solenoid pilot operated
c) control valves • manual override
• identify the need in a circuit for directional control, • intrinsically safe
soft start/dump, flow regulation, • explosion proof
non-return, shuttle and proof of position valves • reed switches
• identify the main features of 2/2, 3/2, 4/2, • proximity sensors
5/2, 3/3, 4/3, 5/3 spool and poppet valves • micro switches
• identify the different methods of valve actuation • pressure switches
• manual • light sensitive devices
• mechanical • relays
• electrical • stepping relays
• pneumatic
• distinguish between the centre condition of three P2.5.8 Hydro-pneumatic Components
position valves
• all ports closed a) list the uses of hydro-pneumatic components
• service ports open to exhaust • air/oil cylinders
• service ports open to supply ports • intensifiers
• identify unidirectional and bi- • hydro-checks
directional flow restrictors
• outline how logic functions NOT, AND, OR are b) state the advantages of hydro-pneumatic
achieved using systems
98

P2.5.9 Pipe-work and Connectors • sketch circuit diagrams using solenoid valves
and reed switches/proximity sensors
a) distinguish between types of pipes and hoses • multi-cylinder circuits using relay control

b) identify couplings and connectors for h) sketch circuit diagrams with shuttle, differential
components listed in a) pilot and quick exhaust valves

c) state materials of construction of pipes and i) describe hydro-pneumatic circuits for

hoses and give examples of their application • precision movement control
• pressure intensification
P2.5.10 Seals • hydraulic locking

a) identify static and dynamic seals installation P2.5.12 Emergency Fail-safe and Safety
procedures Systems
In accordance with the Machinery Directive,
b) state materials of construction and give describe emergency fail-safe and safety
examples of their application systems.
a) differentiate between ‘emergency’ and
P2.5.11 Circuit and Control Features ‘fail-safe’
Recognition and Use of Pneumatic
and Electrical Component Symbols) b) outline emergency stop procedures using
• interlocks
a) recognise and use ISO standard graphical • fail-safe systems
pneumatic symbols and IEC standard
P2.5.13 Installation and Commissioning
b) sketch single cylinder circuit diagrams Procedures
to control piston movements Describe installation and commissioning
• single cycle and reciprocating action using procedures to be followed:
proof of position and pressure operating valves • planning work to be done and listing
• dwell control by restrictors/reservoirs and timers necessary resources
• speed control by flow regulators • checking component conformance
against technical specification
c) recognise the numerical system ISO standard • following manufacturer’s recommendations
by means of identifying valve ports for installation of a particular component/s
•outline commissioning procedures to be
d) state other methods of identifying ports followed, taking into consideration: safety/risk
• alphabetical assessment; operational specification;
technical specification and start up procedures
e) state method of specifying cylinder • outline the procedures to be followed to ensure
movement by that system/components/s operates at a
• ISO standard satisfactory level of performance
• alphabetical method • outline the procedure to be followed to
ensure that the work place is re-established ‘fit
f) describe multi-cylinder pneumatic circuits for purpose’
(Note: restrict to 3 cylinders only) • completion of all necessary reports/documentation
• sketch circuit diagrams using proof of position
valves as interlocks P2.5.14 Maintenance, Monitoring and Fault
• defi ne the terms ‘pulsed signal’, ‘maintained Finding Procedures
signal’, ‘trapped signal’ Describe maintenance, monitoring and
• illustrate methods of avoiding trapped signals fault-finding procedure:
• cascade system
• logic step sequencer a) Outline the maintenance scheme, involving
performance and health monitoring in terms of:
g) describe multi-cylinder Electro-pneumatic • maintaining cleanliness standard
circuits (Note: restrict to 3 cylinders only) • regular use of diagnostic and test equipment
 99

• analysis of results and actions to be taken c) Describe procedures to follow when

(prognosis) carrying out fault finding, in terms of:
• keeping up to date records and information • identifying and determining the nature of the fault
systems • planning stages
• establishing safe working practices and step by • safe working practices to be followed and
step procedures when dealing with system associated risk assessment
breakdowns/component failures/replacement/ re- • information necessary to effectively carry out
commissioning start up and testing fault diagnosis and rectification process
• application of FAULT-CAUSE-REMEDY
b) List the common faults encountered in Electro- procedures
Pneumatic systems and associated • use of diagnostic equipment and
components and state possible causes and recording results
effects on system performance relating to: • procedures to follow to rectify problems
• incorrect sequence of operations (adjustments, replacements, repair and re-
• incorrect sensor setting commissioning)
• low air supply pressure • establishing system re-start procedures
• air starvation • re-establish work place- ‘fit for purpose’
• incorrect air preparation • completion of all necessary reports/
• erratic operation documentation
• loads lowering/failure to hold position

PNEUMATICS & CONTROL PROGRAMME (P3):

RE 2015/06.01 - P
CETOP (Passport) Occupational Level 3
INTRODUCTION Throughout the programme, emphasis will be placed
upon the development of knowledge relating to
This is a LEVEL 3 Pneumatics Programme, forming ”FUNCTION”, ”OPERATION” and ”APPLICATION”.
the start of a series of competence- based The knowledge-based section will support the
qualifications designed around CETOP development and effective application of Practical
occupational levels. Skills necessary to carry out in a safe and effective
manner that of:
It combines the necessary knowledge and
competence based skills for those people on route • INSTALLATION
to a qualification at level 3, involving the • COMMISSIONING
maintenance and management of pneumatic • PERFORMANCE TESTING
systems. • PREDICTIVE MAINTENANCE AND
MACHINE MANAGEMENT
• SERVICING
CETOP OCCUPATIONAL LEVEL 3 • COMPONENT REMOVAL
AND REPLACEMENT
LEVEL (3) This person will be involved in a broad
and often complex range of activities, often requiring The development of Planning and Preparatory
independent decisions to be made on technical Skills, the use of technical information and
matters concerning specifications, resources or specifications and the formulation and
processes. Planning of work will be a responsibility, implementation of safe working procedures will
as will the finding and rectification of faults. be emphasized throughout all aspects of this
Responsibility for the quality of work undertaken and programme.
the required outcomes are also included.

No part of this publication may be photocopied or otherwise reproduced without the prior permission in writing of the Association.
Whilst the Association does its best to ensure that any information that it may give is accurate, no liability or responsibility of any kind is accepted in this respect by the Association,
its members, its servants or agents. Further copies of this document can be obtained from the CETOP, e-mail: [email protected]. PDF-version of this document can be
obtained from the CETOP web-site: www.cetop.org.
100
 101

PRACTICAL TASK ASSESSMENT (P3)

METHODOLOGY AND ASSESSMENT
Assessment Requirements
The programme can be offered via a range of
learning mode devised by the Approved In practical tasks, candidates must on at least
Centres but it is envisaged that distance two occasions, prove their ability to carry out
learning supported by a series of centre- the following:
based modules will be the normal system
used. Candidates will be expected to P3.1.1 Machine function and operating
complete a series of assignments principles identified
throughout the programme of study to P 3.1.2 Components correctly identified
reinforce the learning process and P3.1.3 Function and operation of individual
attend the programme of centre-based modules. sub-circuits correctly identified
P3.1.4 Machine control inputs and outputs identified
Final assessment for the knowledge-- based
Assessed Ability
P 3.2 Assemble pneumatic/Electro-pneumatic
units will be by means of a written examination of system from given information.be carried out
2½ hours duration. These will be prepared and at the approved centre during the education
offered at approved centres or at an engaged programme period. It could be arranged on
external examination centre. The pass mark for the one to one base or in groups, candidate/
written examination will be 70%. candidates to tutor.

The expected completion time for this competence P3.2.1 Components selected and conformance
based programme is 1 - 2 years and will require a checked against system specification
high level of personal commitment to study and P3.2.2 Installation/Action plan prepared
research the subjects within the P3.2.3 System assembled in safe and efficient
manner and complying with European
Directives and safety standards
(reference P3.7.18)
Evidence Required
P3.2.4 Setting up/commissioning procedures
Practical task assessments to verify competency followed in accordance with technical
against the agreed performance criteria will be specification
P3.2.5 Start up procedures correctly specified
All candidates taking a level 3 qualification should P3.2.6 System operated
have a minimum of 2 years work based according to specification
experience involving hydraulics verified by their
employer. Assessed Ability
P 3.3 Construct and commission ‘PLC’ controlled
Alternative: Electro-pneumatic system from given
Where candidates do not have 2 years work information.
based experience they can undertake the Evidence Required
qualification but will not receive the award until
they have completed two years of verified P 3.3.1 PLC program correctly designed
employment involving hydraulics. P3.3.2 Components correctly selected for application
P3.3.3 System assembled in safe and efficient
Successful completion of both the knowledge
based and competence based units will result in manner
the award of a CETOP Level 3 Pneumatics & P3.3.4 Applies monitoring and editing features to
Control Qualification Certificate (P3). correct or modify the program as necessary
Candidates successfully completing only one unit
will receive a CETOP Unit Certificate. P3.3.5 System operated according to specification
102

Assessed Ability KNOWLEDGE BASED UNIT (P3)

P 3.4 Identify and rectify faults in pneumatic/
Electro-pneumatic systems. CONTENTS

Evidence Required P 3.7.1 Fundamental and Scientific Principles

P 3.4.1 Malfunction correctly identified P 3.7.2 Application of Fundamental Principles
P 3.4.2 Correct procedures used for fault finding P 3.7.3 Fundamental Electrical Principles
P 3.4.3 Systems correctly and safely isolated P 3.7.4 Electrical/ Electronic Components
P 3.4.4 Faulty component(s) correctly identified, P 3.7.5 Solenoid Valves
repaired/replaced and correctly adjusted P 3.7.6 Electro-Pneumatic Systems
as necessary P 3.7.7 Proportional Valve Technology
P 3.4.5 Cause and effect correctly assessed P 3.7.8 Electrical noise/ suppression
P 3.7.9 Pneumatic Control Systems
Assessed Ability P 3.7.10 Digital Control Circuits
P 3.5 Establish documented procedures and P 3.7.11 Relay Ladder Circuit Diagram
carry out preventative maintenance and P 3.7.12 Programmable Logic Controller (PLC)
monitoring of pneumatic/ P 3.7.13 Field Bus Systems
electro-pneumatic systems. P 3.7.14 Vacuum Technology
P 3.7.15 Systems and Control Features
Evidence Required (Recognition and use of pneumatic,
P 3.5.1 System assessed to determine service/ Electro-pneumatic, electrical and
maintenance schedule requirements electronic symbols)
P 3.5.2 System assessed to determine routine P 3.7.16 Installation and Commissioning
monitoring requirements Procedures
P 3.5.3 Documented system established includ- P 3.7.17 Maintenance, Monitoring and Fault Finding
ing safety requirements/risk assessment Procedures
P 3.5.4 Performance testing carried out and P 3.7.18 Safety of Machinery, Pneumatic/Electro-
results recorded pneumatic equipment used on machines
P 3.5.5 Pneumatic and electrical input/output conforming to European Directives &
signals checked and recorded Standards
P 3.5.6 Manufacturers recommendations and
specifications checked against results
P 3.5.7 Safe working practices followed at all KNOWLEDGE BASED UNIT -
times WRITTEN EXAMINATION SPECIFICATION

Assessed Ability The examination paper will contain 8 questions

P 3.6 Identify and apply relevant regulations for integrating the above 18 sections.
the safe installation and operation of
Pneumatic/Electro-pneumatic circuits.
• Examination duration recommended will be a
Evidence Required minimum of 2½ consecutive hours
P3.6.1 Legal Regulations: Machinery Directive
• Candidates will be expected to attempt 5
(EU), EMC, ATEX... questions
P3.6.2 List basic safety principles
• Each question will carry equal marks
and components • Pass mark will be 70%
P3.6.3 Safety related parts of power
and control systems.
Where calculations and formulae are involved, all
progressive stages of the calculation together with
the corresponding units must be shown.
Note: Preparation for practical task
assessment can be a group activity or it
could be carried out on a ”one to one”
basis or in groups between the candidate
and the assessor. Evidence will be
obtained by non-intrusive observation,
questioning or written and verbal reports.
 103

POWER PNEUMATICS AND CONTROL d) Control of movement

- (Knowledge Based Unit) • speed
• stopping or preventing movement
• changing direction
P 3 . 7 . 1 Fundamental and Scientific
Principles P3.7.3 Fundamental Electrical Principles
Describe the fundamental principles of power Describe the fundamental principles and control,
transmission by pneumatics and associated applicable to the use and application of
scientific principles underlying their use. electrical/electronic technology.
a) List the basic components and describe
their function • state and use the relationship between voltage,
• prime movers, compressor, coolers, air receiver, current, resistance and power
dryers and pipe-work. • state the relationship between movement,
magnetism and current
b) Know the quantities and units • meaning of the term inductance and its effect
• pressure, force, area, air consumption, flow upon DC circuits
rate, speed/velocity, torque and power. • meaning of the term capacitance and its effect
• Conversion of units upon DC circuits
c) Know the formulae relating to: • meaning of the terms amplitude, frequency,
• pressure, force, area, air consumption, flow periodic time and RMS
rate, speed/velocity, torque and power • defi ne the terms digital and analogue associated
with control systems
d) State and use the relationship between: • describe the fundamental principles of open and
• pressure, force and area closed loop control
e) List the advantages and disadvantages of
pneumatic systems compared to: P3.7.4 Electrical/Electronic Components
• mechanical systems Describe the function and application of
• electrical systems electrical/electronic components.
• hydraulic systems • resistors
• capacitors
P 3 . 7 . 2 Application of the Fundamental • potentiometers
Principles • transformers
Describe the application of the • diodes
fundamental principles relating to: • switches (two way and three way)
• relays
a) Relationship between flow rate, pressure • proximity and limit switches
drop, pipe size and length • pressure switches
• using a P/V diagram, state the relationship • position sensors
between pressure, volume and temperature and
work done for isothermal, polytrophic and P3.7.5 Solenoid Valves
adiabatic compression of air Describe the function, operating principles,
• define the term relative humidity and explain the application and mounting arrangements of
effect it has when air is compressed and when solenoid operated valves.
compressed air passes through a system.
a) types of solenoids
b) Control of Pressure • switching (AC and DC)
• distinguish between gauge pressure and • proportional
absolute pressure
• compression ratio b) solenoid features
• pressure relief • manual override, manual reset
• pressure reduction • explosion proof (reference to intrinsically safe)
• pressure measurement
c) types of valve
c) Control of Flow • direct operated
• directional • internal pilot operated
• soft start/dump • external pilot operated
• flow control, bi-directional
• flow control with by-pass d) types of solenoid suppression
• non-return • AC circuits
• flow coefficients and conversion • DC circuits
 104

P3.7.6 Electro-pneumatic Systems b) Applications

Describe the function, applications and mounting. • simple application
• Valve terminal • complex application
• Island • ‘hazardous area’ application

P3.7.10 Digital Control Circuits

P 3.7.7 Proportional Valve Technology Prepare/describe digital control circuit diagrams
Describe the fundamental principles of using graphical symbols for listed circuitry.
proportional valve technology. • manual control
• automatic control
a) list its potential applications compared to • sequence control (time-based and feedback)
solenoid switching valve techniques • automatic control incorporating
fail safe techniques (including manual reset)
b) describe the operation of proportional valves
• Pressure Control P3.7.11 Relay Ladder Circuit Diagram
• Flow Control Prepare/describe relay ladder circuit diagrams in-
corporating the following terms:
c) describe in block diagram form, the components
of a typical proportional valve electronic amplifier • ‘AND’, ‘OR’, ‘NOT’ and ‘MEMORY’
and explain the meaning of: • latching and unlatching
• gain adjustment
• deadband compensation P3.7.12 Programmable Logic Controller (PLC)
• ramp controls Describe the function and operating principles of a
• dither Programmable Logic Controller (PLC) in the con-
• pulse width modulation trol of Electro-Pneumatic systems.

d) explain the recommended practices a) outline the concept of a PLC

for installing proportional electronic control in
terms of: b) list the advantages compared with relay circuits
• power supply requirements
• enable signals c) describe typical PLC hardware and give
• input signal generation examples of its use relating to:
• cable shielding • an installation with a simple program
• earthing • an installation with an enhanced program
• interfacing to PLC’s • programming devices
• memory systems
P3.7.8 Electrical noise/suppression • analogue to digital and digital to analogue
conversion
a) state the causes and possible effects • data acquisition
of electrical noise in electrical/electronic systems • monitoring
and identify the standard precautions for
eliminating the effects. d) describe using block diagrams and symbols a
• correct earthing and screening simple PLC controlled Electro-pneumatic system
• correct location of sensitive components including:
• use of opto-isolators • power supply
• use of filters to suppress Electro-magnetic gen- • fusing
erated noise • coil suppression
• effects of ground loops • emergency stop switching

b) identify the degrees of ingress protection e) describe using ladder logic diagrams basic
applied to enclosures (‘IP’ codes) program functions:
• single and multiple ‘AND’ and ‘NAND’
P3.7.9 Pneumatic Control Systems • single and multiple ‘OR’ and ‘NOR’
Describe the control methods and applications • single and multiple latching
used to achieve sequential control. • timing
• counting
a) Methods • flags/markers
• Cascade • shift register
• Pneumatic Logic • jumps and loops
• Pneumatic Sequencer
 105

f) describe the use of a PLC used to control:

c) Applications
• automatic time based sequence control of two or
How can vacuum be used ?
more actuators
Describe applications using
• automatic sequence control of two or
vacuum technology.
more actuators using proof of position
feedback d) Calculation
Force on a vacuum gripper.
g) describe using block diagrams the following Force on a suction cup, friction factor.
program types: Evacuation time, ejector pulse, air saving.
• alternative (stored in memory simultaneously) Efficiency of a vacuum generator. Energy
• parallel cost.
• multi-tasking
P3.7.15 Circuit and Control Features
P3.7.13 Field Bus Systems (Recognition and use of pneumatic,
Describe the principles and characteristics of Electro-pneumatic, electrical and
Field Bus Systems as applied to control electronic symbols)
technology: Describe and interpret Electro-pneumatic circuits
and associated methods of control,
a) outline the concept of Field Bus Systems including handling systems, positioning systems,
fail safe methods:
b) identify different methods of transmitting data • Recognize and use current graphical pneumatic,
(protocols) Electro-pneumatic, electrical and electronic
• Profibus ‘DP’ symbols (IEC and ISO standards)
• Device Net • Use methods to describe the running:
• ASI Functional diagram or function chart for
• Interbus ‘S’ sequential process (IEC standard)
• FIPIO
• CANopen P3.7.16 Installation and Commissioning
Procedures
c) describe typical Field Bus compatible Describe installation and
hardware commissioning procedures to be
• valve islands followed:
• valve/sensor return islands • planning work to be done and listing necessary
• input/output modules, nodes resources
• gateways • checking component conformance against
technical specification
d) describe the programming concept used with • following manufacturer’s recommendations
Field Bus Systems for installation of a particular component/s
•outline commissioning procedures to be fol-
P3.7.14 Vacuum Technology lowed, taking into consideration: safety/risk
assessment, operational specification,
a) Describe the fundamental and scientific technical specification and start up procedures
principles relating to vacuum pressure. • outline the procedures to be followed to ensure
Vacuum definition, technical data, that system/components/s operates at a
thermodynamic topic. satisfactory level of performance
Know the relating to flow rate in relation • outline the procedure to be followed to ensure
to vacuum pressure. that the work place is re-established
‘fit for purpose’
b)List of vacuum circuit components • completion of all necessary reports/
and describe their functions. documentation
Vacuum generators: Venturi principle, pumps.
Vacuum actuators: Suction cups (material, P3.7.17 Maintenance, Monitoring
shapes, size) modular vacuum grippers. and Fault Finding Procedures
Specific components adapted for vacuum Describe maintenance, monitoring and
control (valves, sensors) faultfinding procedures:
Piping of a vacuum circuit (diameter, length,
material)
 106

a) Outline the maintenance scheme, involving P3.7.18 Safety of Machinery,

performance and health monitoring in terms of: Pneumatic/ Electro-pneumatic
• maintaining cleanliness standard equipment on machines conforming to
• regular use of diagnostic and test equipment European Directives and Standards
• analysis of results and actions to be taken Describe:
(prognosis) a) Safety requirements for pneumatic systems and
• keeping up to date records and information components.
systems • Interpret the essential safety requirements in
• establishing safe working practices and step by order to achieve conformity with European
step procedures when dealing with system Legislation on machinery safety
breakdowns/component failures/replacement/ • Identify and prevent hazards from pneumatic and
re-commissioning start up and testing. Electro-pneumatic equipment and give the
solutions for
b) List the common faults encountered in • isolation and purging
Electro-Pneumatic systems and associated • separation of energy sources
components and state possible causes • reinstating of energy sources
and effects on system performance relating to: • general stop
• emergency stop
• incorrect sequence of operations • manual starting
• incorrect sensor setting
• low air supply pressure b) Emergency fail-safe and safety systems In
• air starvation accordance with the Machinery Directive,
• incorrect air preparation describe emergency fail-safe and safety systems.
• erratic operation • differentiate between ‘emergency’ and ‘fail-safe’
• loads lowering/failure to hold position • outline emergency stop procedures using
• interlocks
c) Describe procedures to follow when • fail-safe systems
carrying out fault finding, in terms of:
• identifying and determining the nature of the fault c) Risk analysis in accordance with the Machinery
• planning stages Directive
• safe working practices to be followed and • Compliance with ATEX Directive
associated risk assessment
• information necessary to effectively carry out
fault diagnosis and rectification process
• application of FAULT-CAUSE-REMEDY
procedures
• use of diagnostic equipment and recording
results
• procedures to follow to rectify problems
(adjustments, replacements, repair and re-
commissioning)
• establishing system re-start procedures
• re-establish work place- ‘fit for purpose’
• completion of all necessary
reports/documentation
Addresses of CETOP Member Associations
CETOP has 18 member associations with more than 1,000 companies from 17 European countries.
Our member associations are:

Belgium: INDUMOTION Netherlands: FEDA Sweden: HPF

INDUMOTION vzw/asbl Stephensonweg 14 P.O. Box 22 307
Villalaan/Av. des villas 83 4207 HB Gorinchem 104 22 Stockholm
1190 Brussel/Bruxelles NETHERLANDS SWEDEN
BELGIUM Phone: +31 183 822 992 Phone: +46 8 508 938 00
Phone: +32 471 20 96 73 E-Mail: [email protected] Fax: +46 8 508 938 01
E-Mail: [email protected] Web: www.feda.nl E-Mail: [email protected]
Web: www.indumotion.be Web: www.hpf.se
Norway: HPF
Czech Republic: CAHP Filipstad Brygge 2 · 1397 Vika Switzerland: GOP
Novotného lávka 200/5 0114 Oslo Gesellschaft für Fluidtechnik Schweiz
116 68 Praha 1 NORWAY Tödistrasse 42 · P.O. Box 1507
CZECH REPUBLIC Phone: +47 22 340 000 8027 Zurich
Phone: +420 221 082 203 Fax: +47 22 340 001 SWITZERLAND
E-Mail: [email protected] E-Mail: [email protected] Phone: +41 43 305 0982
Web: www.cahp.cz Web: www.hpf.no Fax: +41 43 305 0998
E-Mail: [email protected]
Denmark: BITVA Poland: Corporation Web: www.gop-verband.ch
Børsen of Hydraulic and Pneumatic
1217 Copenhagen K Drives and Controls Switzerland: SWISSMEM
DENMARK c/o Wrocław University of Pfingstweidstrasse 102
Phone: +45 3374 6112 Technology, Department of P.O. Box
Fax: +45 3374 6080 Operation and Main­tenance of 8037 Zurich
E-Mail: [email protected] Logistics, Transportation SWITZERLAND
Web: www.bitva.dk and Hydraulic Systems Phone: +41 44 384 4111
ul. Łukasiewicza 7/9, room 308 E-Mail: [email protected]
Finland: FHPA 50-371 Wrocław Web: www.swissmem.ch
Kaskitie 12 POLAND
33540 Tampere Phone: +48 71 3202667 Turkey: AKDER
FINLAND E-Mail: [email protected] Perpa Ticaret Merkezi, B Blok,
Phone: +358 3 255 0905 Web: cpl.pwr.edu.pl Kat: 12, No: 2087
E-Mail: [email protected] 34384 Okmeydani/ Şişli-Istanbul
Web: www.fhpa.fi Romania: FLUIDAS TURKEY
14, Cutitul de Argint Street Phone: +90 212 210 34 23
France: ARTEMA 040558 Bucharest Fax: +90 212 222 19 71
Maison de la Mécanique ROMANIA E-Mail: [email protected]
39 rue Louis Blanc - CS 30080 Phone: +40 21 336 3991 Web: www.akder.org
92038 La Défense Cedex Fax: +40 21 337 3040
FRANCE E-Mail: [email protected] United Kingdom: BFPA
Phone: +33 1 4717 6309 Web: www.fluidas.ro Cheriton House, Cromwell Park
Fax: +33 1 4717 6370 Chipping Norton
E-Mail: [email protected] Slovenia: FTS Oxfordshire OX7 5SR
Web: www.artema-france.org Dimičeva 13 UNITED KINGDOM
1000 Ljubljana Phone: +44 1608 647 900
Germany: VDMA SLOVENIA Fax: +44 1608 647 919
Fachverband Fluidtechnik Lyoner Phone: +386 1 5898 308 E-Mail: [email protected]
Strasse 18 Fax: +386 1 5898 200 Web: www.bfpa.co.uk
60528 Frankfurt am Main E-Mail: [email protected]
GERMANY Web: www.gzs.si
Phone: +49 69 6603 1332 Fax:
+49 69 6603 1855 Spain/Portugal: AIFTOP
E-Mail: [email protected] ESEIAAT – Edifici TR4 (Labson)
Web: www.fluid.vdma.org c/ Colón n° 7–11 CETOP General Secretary
UPC-Campus de Terrassa Sylvia Grohmann-Mundschenk
Italy: ASSOFLUID 08222 Terrassa (Barcelona) Lyoner Strasse 18
Viale Fulvio Testi, 128 SPAIN 60528 Frankfurt am Main
20092 Cinisello Balsamo (MI) Phone: +34 937 398664 GERMANY
ITALY E-Mail: [email protected] Phone: +49 69 6603 1201
Phone: +39 02 2901 0411 Web: www.aiftop.es Fax: +49 69 6603 2201
Fax: +39 02 6570 266 E-Mail: [email protected]
E-Mail: [email protected] Web: www.cetop.org
Web: www.assofluid.it
108

IMPRINT

Editor:

CETOP Education Commission

CETOP Vice President Education: Sten-Ove Claesson,

HYDAC AB – Sweden

CETOP Education Secretary:

Address of CETOP Education Secretariat:

CETOP General Secretariat

Lyoner Strasse 18 · 60528 Frankfurt am Main – GERMANY
Tel.: +49 69 660 313 19 · Fax: +49 69 660 326 58
E-Mail: [email protected] · Web: www.cetop.org

Design/DTP:
Buero for Visual Communication, Dipl.-Designer Rainer E. Rühl
Alsheim, Germany

© CETOP, 2015 · Revised 2017

No part of this publication may be photocopied or otherwise reproduced without the prior permission in
writing of the Association.

Whilst the Association does its best to ensure that any information that it may give is accurate, no liability or
responsibility of any kind is accepted in this respect by the Association, its members, its servants or agents.
Further copies of this document can be obtained from the CETOP, e-mail: [email protected].
 www.cetop.org

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CETOP General Secretariat

c/o VDMA
Lyoner Strasse 18
60528 Frankfurt am Main
GERMANY
Tel: +49 69 6603 1201
Fax: +49 69 6603 2201
E-mail: [email protected]
Web: www.cetop.org