Hydraulic System Training – Stage 3

Stage 3 is the most advanced course in MGR Fluid Engineering’s hydraulic training programme. It is designed for engineers and senior technicians who already have a solid understanding of hydraulic systems and are ready to develop the skills needed to design, troubleshoot and maintain them to a high level.

The course brings together the most demanding and practically valuable areas of hydraulic engineering: advanced theory and calculations, hands-on system design using Automation Studio, contamination control, fault finding methodology, and safe working with hydraulic systems. Delegates leave with the tools and confidence to approach complex hydraulic challenges — in the field, on the workshop floor, or in a design office. The course is delivered over one day at your site and every delegate receives a full set of course notes and a work pack.

Stage 3 goes deeper into the mathematics of hydraulic systems — the calculations that engineers need to correctly specify, analyse and optimise a hydraulic circuit:

• Pipe and hose pressure drop – how to calculate the pressure losses in pipes and hoses, why this matters for system performance, and how to select the right bore and length
• Heat generation – how heat builds up in a hydraulic system, how to calculate the heat load, and what to do about it
• Hydraulic cylinder sizing – calculating the force, speed and flow requirements for a cylinder application, and how to correctly size a cylinder for the job

These are not theoretical exercises —-they are the calculations that underpin every well-designed hydraulic system, and being able to do them accurately is what separates an engineer who understands hydraulics from one who simply operates it.

he centrepiece of Stage 3 is a practical design exercise: working from a given application, delegates design a complete hydraulic system from scratch. The system must include a reservoir, pump, prime mover, control valve, pipes and hoses, cylinders, filter and instrumentation — and every component must be correctly sized.

Once designed, the system is built and simulated in Automation Studio, so delegates can see how their design performs under realistic operating conditions — pressure, flow and speed all visible in real time. It is the closest thing to real-world design work you can do in a single day’s training, and it brings everything from Stages 1, 2 and 3 together into a single, coherent exercise.

Contamination is the leading cause of hydraulic system failure – and yet it is frequently underestimated or poorly managed. This section covers the theory behind controlling contamination in hydraulic systems: why it happens, how it damages components, what target cleanliness codes mean and how to achieve them, and how to design and maintain a system that keeps contamination under control. Delegates leave understanding not just that contamination matters, but precisely what to do about it.

Hydraulic systems operate at high pressures and contain significant stored energy — working safely around them requires specific knowledge and a systematic approach to risk. This section looks at the main hazards associated with hydraulic systems and the practical steps to mitigate them: safe isolation and de-energisation procedures, the risks of fluid injection injury, working with accumulators, and good housekeeping practices that reduce risk in the long term.

The final section develops a structured, systematic approach to hydraulic fault finding — one of the most valuable skills an experienced hydraulic engineer can have. Working from hydraulic schematics, delegates develop and practise a diagnostic process for identifying and resolving faults in theoretical systems. The emphasis is on method: how to read the symptoms, form a hypothesis, test it logically, and arrive at the correct diagnosis efficiently — without unnecessary disassembly or guesswork.

All MGR training uses Automation Studio — specialist hydraulic circuit simulation software that allows circuits to be built and run in real time, with pressure, flow and speed all visible on screen. At Stage 3, this is at its most powerful: the full design exercise is built and simulated by delegates themselves, giving you the experience of seeing your own design perform — and understanding immediately what works and what needs to change.

Training is delivered on-site at your premises, anywhere in the UK.

Stage 3 is the right course if you or your team:

• Have completed Stages 1 and 2, or have equivalent experience with hydraulic system fundamentals and schematics
• Are responsible for designing, specifying or signing off hydraulic systems
• Lead fault finding and troubleshooting on hydraulic equipment
• Are responsible for hydraulic system maintenance and want a deeper understanding of contamination, failure modes and safe working
• Want a complete, expert-level grounding in hydraulics that covers design, safety and diagnostics in a single day

• Full one-day training session delivered at your site
• Comprehensive course notes covering all topics
• Work pack for reference and reinforcement after the course
• Live hydraulic circuit simulations using Automation Studio
• Certificate of attendance