Mechanical Maintenance


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    201 Introduction to Industrial Maintenance and the Tools of the Trade

    201-01 Working Principles of Simple Machines
    When you complete this lesson you will be able to describe several simple machines used to make work easier. These simple machines are the inclined plane, wedge, lever, screw, pulley, gears, and the wheel and axle.

    201-02 Hand Tools I
    When you complete this lesson, you will be able to explain safety precautions to take when working with hand tools. You will be able to explain and describe various types of wrenches, hammers, screwdrivers, and pliers commonly used in industrial facilities.

    201-03 Hand Tools II
    When you complete this lesson, you will be able to explain and describe various types of saws, files, chisels, punches, vices, clamps, and levels commonly used in industrial facilities.

    201-04 Portable Power Tools
    When you complete this lesson, you will be able to explain some safety precautions to follow when working with portable power tools. You will be able to identify and describe various types of grinders, impact wrenches, power drills, power screwdrivers, and power saws used in industrial facilities.

    201-05 Torque Wrenches
    When you complete this lesson, you will be able to explain the need for torque wrenches in machining and maintenance operations. You will also be able to describe the various types of torque wrenches available and explain the proper procedures for their use.

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    202 Belt Drive Maintenance

    202-01 Introduction to Belt Drive Maintenance
    When you complete this lesson, you will be able to knowledgeably discuss the general use and maintenance of belt drive systems.

    202-02 V-Belts
    When you complete this lesson, you will be able to explain the design and use of the most common variations of V-belts.

    202-03 Positive Traction Belt Drives
    When you complete this lesson, you will be able to describe the major components and proper operation of positive traction drive belt systems used in an industrial facility.

    202-04 Sheave Maintenance
    When you complete this lesson, you will be able to describe the design and operation of sheaves and explain basic techniques employed to maintain them.

    202-05 Introduction to Conveyor Systems
    When you complete this lesson, you will be able to identify basic conveyor designs and explain how various general configurations are used to move different products and materials from point to point.

    202-06 Conveyor System Design
    When you complete this lesson, you will be able to describe the components of a typical belt conveyor used in an industrial setting. In addition, you will be able to identify the equipment commonly found in large scale, industrial conveying systems, and describe the purpose of each piece of equipment.

    202-07 Conveyor Belt System Inspection and Operation
    When you complete this lesson, you will have the ability to describe the equipment that is used to protect plant personnel and conveying system equipment.

    202-08 Conveyor Belt Installation and Repair
    When you complete this lesson, you will be able to describe the basic technique used to install and adjust new belting on a large industrial conveyor.

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    203 Bearing Maintenance

    203-01 Introduction to Bearings
    When you complete this lesson, you will be able to explain the basic concepts behind the use of bearings. In addition, you’ll be able to describe their mechanical functions, loading forces, common lubricants, main classifications, and the types of friction they encounter.

    203-02 Rolling Contact Bearings
    When you complete this lesson, you will be able to identify the most common types of rolling contact bearings, and recognize some of their design considerations and common operating characteristics.

    203-03 Sliding Surface Bearings
    When you complete this lesson you will be able to identify the most common types of sliding surface bearings, and recognize some of their design considerations and common operating characteristics.

    203-04 Bearing Installation and Removal
    When you complete this lesson, you will be able to explain some basic techniques for the installation and replacement of rolling contact and sliding surface bearings.

    203-05 Bearing Seals
    When you complete this lesson, you will be able to describe and identify the seals most commonly used on bearings, their specific applications, and their design considerations.

    203-06 Troubleshooting Bearing Failures
    When you complete this lesson, you will be able to recognize symptoms that may indicate failing bearings. In addition, you’ll be able to troubleshoot bearing failures and use the information you gain to prevent a reoccurrence.

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    205 Gear Maintenance

    205-01 Introduction to Gear Drives
    When you complete this lesson, you will be able to describe and explain the function of a gear and define common terms utilized working with gears and gear drives.

    205-02 Types of Gears
    When you complete this lesson, you will be able to describe six common types of gears used in industrial facilities.

    205-03 Maintaining Gear Drives
    When you complete this lesson, you will be able to analyze and troubleshoot common gear drive problems. You will also be able to explain factors affecting gear backlash and proper gear lubrication.

    205-04 Clutches
    When you complete this lesson, you will be able to explain the purpose of clutches and identify the operating principles of common industrial clutch designs.

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    207 Lubrication of Rotating Machinery

    207-01 Lubrication Selection and Sampling in Rotating Machinery
    When you complete this lesson, you will be able to describe factors that influence the selection of lubricants. In addition, you’ll be able to explain how to monitor the condition of lubricant.

    207-02 Lubrication Failures and Management in Rotating Machinery
    When you complete this lesson, you will be able to describe the process and the importance of good lubrication management.

    207-03 Lubrication Analysis in Rotating Machinery
    When you will complete this lesson, you will be able to discuss the characteristics of lubricants and describe how they influence use.

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    208 Piping and Tubing

    208-01 Pipe Connections and Symbols
    When you complete this lesson, you will be able to describe the methods most commonly used to connect lengths of piping, and identify advantages and disadvantages of each. You will be able to recognize symbols commonly used to indicate types of pipes, pipe-fittings, and welding connections.

    208-03 Piping Construction and Sizing
    When you complete this lesson, you will be able to discuss the materials, sizing methods, and construction techniques used in the construction of pipe systems in industrial facilities.

    208-04 Piping Expansion, Support, and Insulation
    When you complete this lesson, you will be able to explain the effects of changing temperatures on industrial piping and describe ways to allow for those effects.

    208-05 Piping Auxiliaries
    When you complete this lesson, you will be able to describe the design and function of steam separators and traps commonly used in piping systems.

    208-06 Tubing Types and Applications
    When you complete this lesson, you will be able to describe the design and function of tubing. In addition, you’ll be able to apply criteria to appropriately select tubing for various common applications.

    208-07 Tube Fittings and Connection Methods
    When you complete this lesson, you will be able to describe various methods to properly cut and join tubing segments.

    208-08 Tube and Conduit Bending
    When you complete this lesson, you will be able to describe how to properly bend tubing and conduit into a variety of angles and offsets.

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    209 Shaft Alignment

    209-01 Shaft Alignment
    When you complete this lesson, you will be to identify common problems of shaft misalignment and apply practices to properly align shafts.

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    211 Chain Drive Maintenance

    211-01 Introduction to Chain Drives
    When you complete this lesson, you will be able to describe the design and function of typical chain drive systems.

    211-02 Chain Drive Maintenance and Troubleshooting
    When you complete this lesson, you will be able to describe techniques for maintaining and troubleshooting chain drive systems in industrial facilities.

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    213 Lubrication

    213-01 Lubrication Basics
    When you complete this lesson, you will be able to explain how lubrication is used in machinery to reduce friction. In addition, you will be able to explain why certain types of equipment require lubricants with different viscosities.

    213-02 Types of Lubricants
    When you complete this lesson, you will be able to describe the factors you must take into consideration when selecting a lubricant for a specific piece of equipment. In addition, you will be able to identify different viscosity grades and explain what each grade represents.

    213-03 Lubrication Sampling and Analysis
    When you complete this lesson, you will be able to explain the importance of lubrication sampling and describe basic techniques used to collect lubricant samples. In addition, you will be able to explain how to use lubrication schedules to ensure completion of proper preventative maintenance.

    213-04 Lubrication Filtration and Purification
    When you complete this lesson, you will be able to explain how to use mechanical filters and lube oil purifiers to keep lubricating oil free of contaminants. In addition, you will be able to describe methods used to filter and purify lubricating oil in a power plant.

    213-05 Lubrication Delivery Methods and Systems
    When you complete this lesson, you will be able to describe common lubricant delivery methods and systems.

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    215 Valve Selection and Maintenance

    215-01 Introduction to Valves and Their Components
    When you complete this lesson, you will be able to explain the basic design and function of valves, major valve components, and flow control elements.

    215-02 Valve Actuators
    When you complete this lesson, you will be able to discuss the use, selection, and design of various actuators, from simple manual hand-wheels to relatively complex electrical and hydraulic manipulators.

    215-03 Gate Valves
    When you complete this lesson, you will be able to explain the use, selection, and design of a gate valve. You will also be able to describe how different service conditions affect gate valve configuration.

    215-04 Globe Valves
    When you complete this lesson, you will be able to describe the use, selection, and design of globe valves.

    215-05 Butterfly Valves
    When you complete this lesson, you will be able to explain the use, selection, and design of typical butterfly valves found in industrial applications.

    215-06 Ball Valves
    When you complete this lesson, you will be able to explain the use, selection, and design of ball valves found in industrial applications.

    215-07 Check Valves
    When you complete this lesson, you will be able to explain the use, selection, and design of check valves found in industrial applications.

    215-08 Needle Valves
    When you complete this lesson, you will be able to describe the use, selection, and design of a needle valve.

    215-09 Plug Valves
    When you complete this lesson, you will be able to describe the use, selection, and design of plug valves commonly found in industrial settings.

    215-10 Diaphragm Valves
    When you complete this lesson, you will be able to describe the use, selection, and design of the two basic types of diaphragm valves.

    215-11 Pinch Valves
    When you complete this lesson you will be able to describe the use, selection, and design of pinch valves.

    215-12 Safety and Relief Valves
    When you complete this lesson you will be able to describe the use, selection, and design of safety valves and relief valves.

    215-13 Solenoid Valves
    When you complete this lesson, you will be able to describe the overall design and function of various solenoid valves.

    215-14 Valve Positioners
    When you complete this lesson, you will be able to describe the basic design and function of common types of valve positioners used in industrial facilities.

    215-15 Pressure Regulator Valve
    When you complete this lesson, you will be able to describe the basic design and function of common types of pressure regulating valves used in industrial facilities.

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    219 Centrifugal Pumps

    219-01 Introduction to Centrifugal Pumps
    When you complete this lesson, you will be able describe the basic design and function of both single-stage and multistage centrifugal pumps.

    219-02 Centrifugal Pump Design
    When you complete this lesson, you will be able describe various centrifugal pump designs and explain the role design plays in matching a pump to an application.

    219-03 Centrifugal Pump Fundamentals
    Centrifugal pumps are used extensively in plant systems to move liquids through processes under various operating conditions. To effectively operate these systems, you need to know the terminology associated with centrifugal pumps and understand factors that affect centrifugal pump operation.

    219-04 Centrifugal Pump Operation
    When you complete this lesson, you will be able describe the basic start-up and shutdown procedures used on single and multi-stage centrifugal pumps. In addition, you will be able to explain the basic inspections that should be completed on operating centrifugal pumps during each shift.

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    223 Heat Exchangers

    223-01 Heat Exchanger Theory
    When this lesson is completed, the student will be able to explain how heat is transferred from one substance to another via the use of heat exchangers. In addition, they will be able to describe the basic differences between heat exchangers and the supporting equipment.

    223-02 Open Heat Exchanger Design and Operation
    When you complete this lesson, you will be able to explain how open heat exchangers use direct contact to heat condensate and remove non-condensable gases from the condensate. In addition, you will be able to describe the three basic types of open heat exchangers and the operational characteristics of each.

    223-03 Closed Heat Exchangers
    When you complete this lesson you will be able to explain how closed heat exchangers use extraction steam and latent heat to increase the temperature of the condensate and feedwater prior to entering the boiler. In addition, you will be able to describe how extraction steam and heater drains are used to increase the overall efficiency of the plant cycle.

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    225 Compressors

    225-01 Compressed Air Systems
    When you complete this lesson, you will be able to describe the basic classifications of air compressors used in industrial facilities. In addition, you will be able to explain the operation of service air and control air systems.

    225-02 Compressed Air System Components
    When you complete this lesson, you will be able to describe the basic components that make up a typical compressed air system. In addition, you will be able to explain some basic trouble shooting techniques used to detect problems in compressed air systems.

    225-03 Positive Displacement Compressors
    When you complete this lesson, you will be able to explain the basic design and operation of positive displacement air compressors, including both the reciprocating and rotary types.

    225-04 Dynamic Compressors
    When you complete this lesson, you will be able to describe the basic design and operation of dynamic air compressors, including both the centrifugal and axial types.

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    229 Fasteners and Seals

    229-01 Bolted Joints
    When you complete this lesson, you will be able to describe commonly used bolt types and grades and discuss their proper use. You will be able to list common modes of joint failure and identify some preventive measures.

    229-02 O-Rings
    When you complete this lesson, you will be able to describe the design and purpose of O-rings. You will also be able to discuss how to use them successfully.

    229-03 Making Gaskets
    When you complete this lesson, you will be able to describe different types of gaskets and explain common methods for making gaskets from stock materials.

    229-04 Fasteners
    When you have completed this lesson, you will be able to describe the design and identify the purpose of various types of fasteners used in industrial facilities.

    229-05 Packing Material Use and Installation
    When you complete this lesson, you will be able to describe what packing is and identify common packing designs, components, and construction. In addition, you’ll be able to explain general procedures for installation and removal of packing from pumps and valves.

    229-06 Mechanical Seals Use and Installation
    When you complete this lesson, you will be able to describe how mechanical seals work and identify the features of commonly used seal types. In addition, you’ll be able to explain proper seal care.

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    231 Positive Displacement Pumps

    231-01 Introduction to Positive Displacement Pumps
    When you complete this lesson, you will be able to describe the basic design and operation of positive displacement pumps and identify operating conditions under which they are commonly implemented. Additionally, you will be able to discuss the operational differences between the two main classes of positive displacement pumps, which are reciprocating and rotary.

    231-02 Reciprocating Positive Displacement Pumps
    When you complete this lesson, you will be able to describe the design and function of reciprocating positive displacement pumps commonly used in industry.

    231-03 Displacement Pumps
    When you complete this lesson, you will be able to describe the design and operation of rotary positive displacement pumps commonly used in industry.

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    243 Hydraulics

    243-01 Introduction to Hydraulics
    When you complete this lesson, you will be able describe the basic components that comprise a typical hydraulic circuit and explain the function of each. In addition, you will be able to explain the use of hydraulic multiplication to increase the capacity of the hydraulic system.

    243-02 Hydraulic Systems
    When you complete this lesson, you will be able to identify and describe the purpose of the various components used in hydraulic circuits. In addition, you will be able to describe the components used to control flow through a hydraulic circuit.

    243-03 Hydraulic Fluids
    When you complete this lesson, you will be able to identify the three basic types of hydraulic fluids. In addition, you will be able to describe some of the considerations that need to be taken into account when selecting a hydraulic fluid for a specific hydraulic circuit.

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    271 Vibration

    271-01 Vibration Introduction
    When you complete this lesson, you will be able to define basic terms and measurement units associated with vibration. You will also be able to describe the relationship between a machine’s operating speed and vibration problems.

    271-02 Vibration Causes and Characteristics
    When you complete this lesson, you will be able to describe the characteristics of common, vibration-causing mechanical faults.

    271-04 Plant Vibration Program
    When you complete this lesson, you will be able to describe a typical plant’s vibration program and discuss how it contributes to the plant’s operational readiness.

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    273 Boiler Repair

    273-01 Boiler Tube Repair
    When you complete this lesson you will be able to describe different types of tube assemblies which may need repair in a boiler. You will be able to list common causes of these leaks and procedures for repairing the tube and tube assemblies.

    273-02 Inspecting the Fireside of a Boiler I
    When you complete this lesson you will be able to explain some specific items to look for when doing a fireside inspection on the watertubes of a large watertube boiler.

    273-03 Inspecting the Fireside of a Boiler II
    When you complete this lesson you will be able to explain some specific things to look for when doing a fireside inspection on the superheaters, reheaters, economizers, ash hoppers, baffles, sootblowers, and the boiler bottom seal on the fireside of a large watertube boiler.

    273-04 Inspecting the Waterside of a Boiler
    When you complete this lesson you will be able to explain some specific things to look for when doing a waterside inspection on steam drums, moisture separators, headers and tubes of a large watertube boiler.

    273-05 Inspecting a Boiler’s Exterior
    When you complete this lesson you will be able to describe some specific areas to look at, and what to look for when inspecting the exterior of a large watertube boiler.

    273-06 Waterside and Fireside Cleaning of a Boiler
    When you complete this lesson you will be able to explain some methods and procedures for cleaning and testing the waterside and fireside of a large watertube boiler.