Embed Size (px)
Citation preview
[email protected] • www.egeniuses.net
Electrical Maintenance
You Will Learn:
The installation, operation, maintenance and management of boiler plants
The steam and combustion processes
Safe boiler operation techniques
About pollutants and the technologies that exist to reduce emission levels
How to achieve peak boiler plant efficiencies
How to identify and troubleshoot boiler problems quickly and efficiently
Who Should Attend:
Senior Boiler Plant Operators, Repairers & Installers
Boiler Plant Construction Managers
Plant Engineers
Operation, Maintenance, Inspection & Repair Managers, Supervisors & Engineers
[email protected] • www.egeniuses.net
Mechanical Engineers & Technicians
Design Engineers
Insurance Company Inspectors Consulting Engineers
The Program:
Air Compressor -
Fundamentals
Compressor Theory and Classifications
Operating Characteristics of Selected Compressors
Matching of Characteristics of Compressors to
Applications
Positive Displacement Compressor Components
Air Compressor Intercoolers
Air Compressor Aftercoolers
Compressors with Dryers
Air Compressor Sealing Mediums
Positive Displacement Reciprocating Compressor
Components
Air Compressor -
Maintenance
Air Compressor Disassembly
Air Compressor Inspections
Replacement of Defective Parts on Air Compressors
Air Compressor Reassembly
[email protected] • www.egeniuses.net
Air Compressors –Positive
Displacement - Overhauls
Multi-Stage Piston Air Compressor Overhaul
Positive Displacement Screw Compressors - "Wet" or
"Dry" Type
Screw-Type Air Compressor Overhaul
Bearing Fundamentals
Loading and Bearing Types
Bearing by Type
Bearing Operating Characteristics
Sliding Surface Bearings
Principles of Rolling Contact Bearings
Bearing Component Matching Type
Identification of Seals Used With Bearings
Use of Seals
Bearing Selections
Bearing Lubrication
Types and Uses of Lubricants
Lubrication for Sliding and Rolling Surfaces
Identification of Lubrication Characteristics by Bearing
Types
Proper Lubrication Techniques
Bearing Maintenance
Bearing Disassembly
Removal of Sliding Surface Bearings
Removal of Rolling Contact Bearings
Sliding Surface/Rolling Contact Bearings Inspection
[email protected] • www.egeniuses.net
Bearing Inspections
Sliding Surface / Rolling Contact Bearing Repair
Procedures
Replacement of Defective Parts
Installation of Siding Surface Bearings
Installation of Rolling Contact Bearings
Drive Belts
Drive Belts Used in the Plant
Use of Drive Belts (V-Belts, Gear Belts, Flat Belts)
Sheaves Used in the Plant
Use of Sheaves in the Plant
Drive Belt Adjustments
Drive Belt Replacement
Gaskets and O-Rings
Gasket Creation
O-Ring Creation
O-Ring Selection
Removal of Sealing Mediums
Installation of Sealing Mediums
Heat Exchanger
Fundamentals
Heat Exchanger Theories
Heat Exchanger Types and Characteristics
Heat Exchanger
Maintenance
[email protected] • www.egeniuses.net
Heat Exchanger Fouling, Corrosion, and Erosion
Heat Exchanger Tube Cleaning
Heat Exchanger Inspections
Heat Exchanger Testing
Heat Exchanger Repairs
Removal and Replacement of Heat Exchangers
Gauge Glass Repair
Hydraulics - Fundamentals
Incompressibility of Fluids
Basic Components Common to Fluid Power Systems
Fluid Power System Diagramming
Purpose of Actuators
Basic Operations of an Actuator
Fluid Power System Control Valves
Valve Operation in Fluid Power Systems
Purpose of Accumulators
Types of Accumulators
Identification of Fluid Power Pumps
Operating Principles of Fluid Power Pumps
Fluid Power Pump Applications
Identification of Fluid Power Motors
Operating Principles of Fluid Power Motors
Fluid Power Motor Applications
Identification of Fluids and Additives Used in
Hydraulic Systems
Fluid Characteristics
Fluid Applications
Fluid Power System Reservoirs
Purpose of Filters
[email protected] • www.egeniuses.net
Hydraulic System Heat Exchangers
Hydraulics - Maintenance
Fluid Power System Vendor Manuals
Identification of Fluid Power Component Malfunctions
Fluid Power System Problems and Possible Remedies
Location of Various Components of a Fluid Power System
Types of Repairs Made to Selected Fluid Power Components
Replacement of Parts and Fluid Power Components
Fluid Power Component Replacement
Fluid Power System Routine Maintenance Activities
Fluid Power Pump System Routine Maintenance
Fluid Power Motor Routine Maintenance
Machine Shop - Grinders, Saws and Drills
Grinding Wheel Dressing and Truing
Grinding of Parts Parallel and to Size
Procedure to Saw to Layout Lines on Band Saw
Procedure to Drill Holes to Layout Lines
Selection of Correct Speed to Drill Size and Material
Procedure to Drill Holes Through the Center of Round Stock
Procedure to Countersink, Counterbore, and Spotface on a Drill Press
Procedure to Ream Holes to Size on a Drill Press
Tap Types and Thread Classifications
Procedure to Tap Holes Using a Drill Press
Machine Shop - Lathes
[email protected] • www.egeniuses.net
Operator Control of Engine Lathe
Use of a Steady Rest
Remove and Install Chucks and Face Plates With Cam Locks
Precision Centering Work in a 4-Jaw Chuck
Facing in a Chuck
Drilling on a Lathe
Alignment of Lathe Centers
Mount Workpieces Between Centers
Center Drill Work Between Centers
Straight Turning Between Centers
Straight Turning Work Held in a Chuck on an Engine Lathe
Taper Turning with the Tailstock Off-Set Method
Cutting Steep Tapers and Chamfers
Taper Turning on a Lathe With a Taper Attachment
Radius and Fillet Turning
Mount, Face, and Turn Work on a Mandrel
Machine Reaming on a Lathe
Parting and Grooving on a Lathe
Boring on a Lathe
Knurling of a Workpiece
Cutting External Unified Standard Screw Threads
Cut Internal Unified Standard Screw Threads
Straighten a Shaft
Grind a Right-Hand Turning Tool
Grind a Right-Hand Facing Tool
Grind a Radius Tool
Grind a Round Nose Form Tool
Grind a 60 Degree Threading Tool
Reverse the Jaws in a 4-Jaw Independent Chuck
Change the Jaws in a 3-Jaw Universal Chuck
Reverse the Jaws in a 3-Jaw Universal Chuck With Cap Screw Mounted Jaws
[email protected] • www.egeniuses.net
Machine Shop - Layout/Bench Work
Rough Layout of a Workpiece
Precision Layout of a Workpiece
Stock Sawing With a Hand Hacksaw
Straight and Draw Filing of Metal
Hole Sizing With Hand Reams
Hand Methods of Deburring Parts
Hand Methods of Removing Broken Studs
Tapping Threads by Hand
Cutting Threads by Hand Using a Threading Die and Tap
Cutting Threads by Machine Using a Threading Die
Broaching of a Keyway Using an Arbor Press
Operate a Powered Keyway Cutter
Machine Shop - Vertical Milling Machines
Vertical Milling Operations Control Familiarity (LAGUN)
Install and Remove a Collect and End Mill
Align Spindle Perpendicular to the Table
Mount and Align a Vise on the Mill Table
Square a Workpiece Clamped to the Mill Table
Square a Workpiece Held in a Vise on a Vertical Mill
Locating, Drilling, and Reaming Holes by Coordinated Method
Locate and Bore Holes - Coordinate Method
Step Drill Holes Accurately to Size
Mill a Slot or a Pocket
Countersinking, Counterboring, and Spot Facing
Mill a Square on a Workpiece
Mill a Hexagon on a Workpiece
Machine a Flat Surface Using a Flying Cutter
Mill Multi-Level Surfaces
[email protected] • www.egeniuses.net
Mill a Fillet with Ball End Mill
Oil Analysis
Fundamentals of Lubrication
Lubrication Sampling Fundamentals
Maintenance, Purification, and Filtration of Oil and Grease Lubricated Systems
Failure Mode Indicators
Lubricant Testing and Analysis
Piping
Fittings
Pipe Joining Methods
Pipe Joining Methods Explained
Use of Pipe Fittings
Pipe Hangers and Support Systems
Pipe Hangers and Support System Operations
Erecting Piping Runs
Piping and Instrumentation Drawing Symbols
Interpretation of Piping and Instrumentation Drawings
Piping Symbols
Precision Measurement
Measuring Device Orientation
Fractional Inch Graduation - Steel Rule
Measurement With Protractors
Outside Thimble Micrometer Ratchet Use
Micrometer "Zero" Calibration
Outside Micrometer Measurements
Measuring with An Inside Micrometer
Measuring with a Telescoping Gauge
[email protected] • www.egeniuses.net
Measuring with a Depth Rule and a Depth Micrometer
Measuring with a Small Hole Gauge
Error in Transferring Measurements
Precision Measuring "Feel"
Vernier Scale Reading
Measuring with Vernier Caliper
Measuring with a Dial Indicator
Checking Concentricity
Measuring with a Dial Caliper
Measuring with a Radius Gauge
Measuring with a Thickness Gauge and a Taper Gauge
Measurement With Wire and Sheet Metal Gauges
Measuring with a Screw Pitch Gauge and a Thread Micrometer
Using a Go / No Go Gauge
Pumps - Centrifugal - Fundamentals
Centrifugal Pump Theories
Centrifugal Pump Components
Identification of Sealing Medium Used Pumps
Performance Issues in Centrifugal Pumps
Cavitation in Centrifugal Pumps
Pumps - Centrifugal - Maintenance
Centrifugal Pump Disassembly
Centrifugal Pump Inspection
Identification of Defective Parts in Centrifugal Pumps
Centrifugal Pump Reassembly
[email protected] • www.egeniuses.net
Pumps - Centrifugal - Overhauls
Horizontal, Single-Stage, Centrifugal Pump Overhaul
Horizontal, Multi-Stage, Centrifugal Pump Overhaul
Vertical, Single-Stage, Centrifugal Pump Overhaul
Vertical, Multi-Stage, Centrifugal Pump Overhaul
Pumps - Positive Displacement - Fundamentals
Pump Theories and Differences
Types of Safety Devices Used for Positive Displacement Pumps
Positive Displacement Pump Applications
Pumps - Positive Displacement - Overhauls
Positive Displacement Pump Disassembly (Screw Pump)
Visual Inspection Of Positive Displacement Pumps (Screw Pump)
Defective Part Replacement (Screw Pump)
Positive Displacement Pump Reassembly (Screw Pump)
Overhaul A Positive Displacement Pump (Gear Pump)
Piston Pump Overhaul
Diaphragm Pump Overhaul
Lobe Pump Overhaul
Vane Pump Overhaul To Criteria In Manuals
Liquid Ring Pump Overhaul
Shaft And Pumping Element Repair
Rigging and Lifting Practices
Proper Use of Riggers Handbook
Types of Rigging and Lifting Equipment
Inspecting the Rigging Equipment
[email protected] • www.egeniuses.net
Safe Working Loads for Various Types of Slings and Hardware
Planning a Rigging and Lifting Job
Proper Use of Rigging and Lifting Equipment
Safe performance of Lifts Using Manually Operated Lifting Devices
Safe Performance of Lifts Using Electric-Powered Lifting Devices
Safe Performance of Lifts with Air-Operated Lifting Devices
Safe Performance of Lifts with Hydraulic Lifting Devices
Safe Performance of Lifts with a Mobile Crane
Safe Movement of Materials/Equipment With a Mobile Crane
Safe Performance of Lifts with a Boom Truck
Safe Movement of Materials/Equipment with a Boom Truck
Safe Usage of Personal Lifting Devices
Scaffolds
Scaffolding Terminology
Types of Scaffolds
Proper and Safe Usage of Scaffolding
Selection of Scaffolding Components for Their Correct Usage
Scaffolding and Stay Assembly
Scaffolding and Stay Disassembly
Shaft Alignment - Laser Aided
The Function of Couplings and Major Coupling Types
Shaft Alignment
Identifying and Correcting Soft Foot
Laser Alignment Safety and System Operating Information
Shaft Alignment Using Laser Based Systems
Laser Alignment Troubleshooting
[email protected] • www.egeniuses.net
Tools
Non-powered Hand Tools - Part 1
Non-powered Hand Tools - Part 2
Power Tools
Measuring Tools
Fasteners
Valve Fundamentals
Valve Theory
Valve Types and Characteristics
Components of Selected Valves
Operation Characteristics of Selected Valves
Characteristics of Valves to Applications
Sealing Mediums Used in Valves
Valve Maintenance
Valve Part and Component Repair
Globe Valve Overhaul
Gate Valve Overhaul
Safety Valve Overhaul
Relief Valve Overhaul
Ball Valve Overhaul
Plug Valve Overhaul
Diaphragm Valve Overhaul
Butterfly Valve Overhaul
Check Valve Overhaul
Control Valve Overhaul
[email protected] • www.egeniuses.net
Welding - Arc
Setup of Electric Arc Welding Equipment for S.M.A.W. Welding in Both Polarities on Steel
Plate
Electric Arc Welding Process for Welding in Various Positions
Welding Positions and Their Orientations
Electric Arc Welding Filler Metal Selection Based on Positions
Matching of Electric Arc Welding Filler Metals to Their Application Positions
Electric Arc Welding Process for Welding in the Flat Position
Usage of Polarities (Direct Current Power) and Current Flow in Electric Arc Welding With
Covered Electrodes
Selection of Electric Arc Filler Metals Based on Application and Positions
Shielded Metal Arc Welding on Carbon Steel Plate to A.W.S. - BU - 2A Prequalified Joint Weld
Procedures
Electric Arc Welding Filler Metal Selection Based on the Flat Position
Matching of Electric Arc Welding Filler Metal Application to Flat Position
Welding Positions and Their Orientations for Pipe Welding
Shielded Metal Arc Welding on Carbon Steel Pipe
Setup of Pipe Coupons for S.M.A.W. Welding in the 2G, 5G, and 6G Fixed Pipe Positions
Fitup Procedure for Chill Rings on Selected Size Pipes
Fitup of Chill Rings on Various Pipe Sizes
Differences Between Mild Carbon Steel Filler Metals and Stainless Steel Filler Metals
Differences in Weldability Between Carbon Steel and Stainless Steel
Explain the Setup of GTAW Equipment for Straight Polarity Welding with Argon Shielding Gas
Demonstrate Setup of GTAW Equipment for Straight Polarity Welding with Argon Shielding
Gas
Joint Fit-Up Procedure for Welding Proper Size GTAW Root Pass on Pipe
Proper Joint Fit-Up Procedure for Welding GTAW Root Pass on Pipe
Argon Backing Gas Purge Systems for Root Protection Against "Sugaring" Pipe
Gas Tungsten Arc Welding on Carbon Steel Tube with Stainless Steel Filler
Shielded Metal Arc Welding on Carbon Steel Pipe with Gas Tungsten Arc Welding Root
[email protected] • www.egeniuses.net
Shielded Metal Arc Welding on Carbon Steel Tube, Gas Tungsten Arc Welding for Root With
Carbon Steel Filler
Welding - Oxyacetylene
Proper Setup for Oxyacetylene Cutting Equipment
Safe Usage of Oxyacetylene Cutting Equipment
Oxyacetylene Cutting
Proper Flame Settings in Relation to Welding Tip Size and Material Thickness
Selection of Cutting Tip Size for Fuel Pressures and Material Thickness to Obtain a
Neutral Flame
Matching of Filler Metal Requirements to Base Metals for Fusion Welding
Matching of Proper Filler Metals to Base Metals
Proper Setting of Oxyacetylene Flame for Fusion Welding
Oxyacetylene Fusion Welding on Carbon Steel
Flame Setting for Oxyacetylene Brazing for Various Silver Alloy Fillers
Reducing/Carburizing of the Flame for Brazing Various Metal Alloys
Matching of Filler Metals for Brazing to Various Types of Base Metals
Matching of Proper Filler Metals to Base Metals to Achieve Strength and Integrity
Oxyacetylene Brazing on Various Metal Alloys
Proper Flame Setting for Braze Welding Various Thickness of Carbon Steel and Cast
Irons
Braze Welding of Various Joint Configurations
Proper Braze Welding of Various Bead Configurations
Braze Welding of Various Base Metal Types
Matching of Braze Welding Filler Metals with Various Base Metals
Oxyacetylene Braze Welding on Carbon Steel and Cast Iron Base Metals
[email protected] • www.egeniuses.net
