
INDUSTRIAL MAINTENANCE TECHNICAL COURSES OUTLINE
Valve Maintenance I & II - 40 Hours
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Fundamentals
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Classifications
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Nomenclature
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Valve selection guide
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Piping definitions
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Sealing mechanisms
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Fluid tightness
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Valve seating
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Gaskets
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Valve stem seals
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Valve Type Design and Construction
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Various valve types
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Pressure Valves
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Safety and Pressure relief Valves
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Self-acting reducing Valves.
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Check valves.
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Foot valves
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Valve sizing
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Control and Automation
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Valve actuators
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Control valves
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Temperature control valves
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Regulators
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Maintenance and Repair
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Parts Manuals
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Valve breakdown and repair
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Troubleshooting various valves
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Codes and regulations
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ASME
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Standards
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Pumps I & II - 40 Hours
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Pump Types
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Terminology and Definitions
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Positive Displacement Pumps
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Rotodynamic pumps
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Special Rotodynamic pumps
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Other Pump Types
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Properties of Liquid
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Terminology and Definitions
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Water
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Oils
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Liquid/solids mixtures
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Liquid/gas mixtures
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Liquid properties
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Flow of Liquids
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Fundamental equations
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Flow losses
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Pressure losses
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Flow measurements
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Pump Theory
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Rotodynamic pumps
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Suction performance
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Positive displacement pumps
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Piping and Pump Systems
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Pressure drops across valves.
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System curves
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Multiple pumping systems
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Water hammer
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Pump hydraulic data.
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Pressure pulsations
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Flow and Regulation Control
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Flow regulations
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Off-on control of constant speed pumps
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Induction motors
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Multispeed gearboxes
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Throttling valves
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Variable speed drives
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Strength in Materials
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Basic materials
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Strength and integrity
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Material selection
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Seals and sealing
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Reciprocating rods
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Rotary shafts
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Liquid seals
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Process liquid seals.
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Mechanical seals
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Heat Exchangers
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Classifications of Heat Exchangers
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Tubular
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Shell and tube
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Plate type
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Extended surface
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Codes and Classifications
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Design Equations of Heat Exchangers
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Arrangement of flow paths
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Design equations
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Heat transfer coefficient
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Heat Exchanger for the single phase
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Heat transfer
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Helical and spiral coils
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Laminar forced convection
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Pressure drops and pumping power.
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Tube side pressure loss
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Pressure drops in helical and spiral coils.
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Crossflow
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Double pipe heat exchangers
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Thermal and hydraulic design
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Design and operational features
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Design considerations
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Total pressure drops.
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Compact heat exchangers
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Plate/fin type
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Tube/fin type
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Heat transfer and pressure drop.
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Problems
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Shell and Tube Heat Exchangers
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Shell type
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Tube bundle type
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Tube layout
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Design criteria
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Heat transfer and pressure drop.
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Heat exchanger fouling
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Basic consideration
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Effects on heat transfer and pressure drop.
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Aspects of fouling
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Controlling fouling
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Gasketed plate type heat exchangers
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Condensers & Evaporators
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Storage, Installations, Operations, & Maintenance
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Troubleshooting
Diesels
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Introduction to Diesels
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Diesel Operating Principle
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Diesel operating principles
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Basic shop tools
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Diesel fuel
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Lubricants
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Coolants
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Bearings
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seals
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Engine Components
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Crankshafts and bearing
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Cylinder head
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Piston and conn rods.
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Gear train, camshaft, engine timing
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Auxiliary systems
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Lubrications
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Cooling
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Starting
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Air intake and exhaust
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Fuel Systems
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Components
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Injector pumps
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PT fuels system
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Injection nozzles
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Governors
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Electrical systems
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Principles of the electrical system
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Batteries
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Ignition circuits
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Starting circuits
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Generator distribution
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Engine performance
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Operations and maintenance
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Testing and diagnosis
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Tune up and adjustments.
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Storage systems
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Introduction to Electricity
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Definitions
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Current, Voltage, Resistance
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Resistance, Resistivity, and conductance
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Voltage, Current, and impedance in single phase systems
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Alternating voltage and current
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Inductive Reactance
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Impedance
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Effects of frequency on the current in a capacitor
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Complex AC circuits
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AC vs DC
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Kirchhoff’s Voltage law
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Ohms Law
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Magnetic fields and magnetic forces
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Magnetic fields
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Mechanical forces by the interaction of magnetic fields
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Coils, magnets, conductors
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Behavior of ferromagnetic material’s
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Conductors and Insulators
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Troubleshooting and emergency repair of three phase motors
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Effects of off standard voltage and frequency on locked rotor torque
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NEMA constraints on voltage and frequency.
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Open phase troubleshooting
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Locating shorted stator coil
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Grounded stator coil
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Squirrel cage and wound round rotor troubleshooting.
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Using Electrical tools for installing and testing verifications
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Mechanical Maintenance of Electrical Machinery
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Maintenance of bearings
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Maintenance of air filters
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Disassembly of electrical motors
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Reassemble of electrical motors.
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Vibrations
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Operation and Maintenance of motor controllers
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Basic starter circuits
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Reading and interpret control diagrams.
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Troubleshooting and maintenance of magnetic controllers
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Solid-state control of motors and drives
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Protection against overloads and short circuits
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Fuses
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Testing fuses
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Breakers
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Interrupting rating of a breaker
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Short circuit protection
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Maintenance and testing of overcurrent relays and breakers.
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Maintenance of switchgear and other electrical apparatus
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General switchgear maintenance
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Overheating contacts and connectors
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Overcurrent and fault currents
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Visual and infrared inspections
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Resonance, harmonics, and their harmful effects in electrical power systems
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Resonance in electric circuits
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Series vs parallel resonance
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Machine Alignment
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Introduction to mechanical Alignment
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Pre alignment checklist
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Types of alignment tools and techniques
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Dial indicator methods
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Rim-Face method
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Reverse Rim Method
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Electronic laser alignment tools
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Rough Alignment
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Correcting soft foot
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Pipe Strain and its effect on precision alignment
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Common assembly errors and its effect on precision alignment
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Key length calculation
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Thermal growth
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Thermal growth calculation
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Precision Alignment
Principles of Machining
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What is machining?
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Speed, Feed, Depth of Cut
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Cutting tool material
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Cutting tool Geometry
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Cutting fluids
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Reference material
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Removing chips from the workpiece
Bearings
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Identify Functions of a Bearing
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Supports
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Guides and Positions
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Differences Between Radial and Axial Loads
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Radial Loads
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Axial Loads
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Common Types of Bearings
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Plain
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Metallic
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Nonmetallic
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Rolling Element
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Radial Ball
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Angular-Contact
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Thrust
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Cylindrical Roller
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Needle Roller
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Cam-Type and Load-Following
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Spherical Roller
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Tapered Roller
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Linear Bearings
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Mounted Bearings
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Pillow Block
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Take Up
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Flange
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Bearing installation and Maintenance
Compressor I & II
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Positive Displacement Compressor
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Reciprocating Compressors
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Major components
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Compressor comparison reciprocating and centrifugal.
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Considerations for upstream separators
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Rotary Compressors
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Helical Screw Compressors
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Operating principle and construction
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Screw compressor staging
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Oil free vs flooded twin screw compressors.
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Centrifugal Gas Compressors
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Where they are used
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Configurations and components
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Compressor power transmission
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Coupling configurations
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Bearing configuration
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Compressor Performance
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Surge control
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Flow coefficient
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Process efficiencies
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Throughput control
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Testing of compressors
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ASME power test code
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Types of performance tests
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Applications considerations
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Natural gas
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Steel industry
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Offshore industry
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Industrial industry
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Petrochemical industry
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Pipe, Fittings, and Auxiliaries I & II
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Definitions
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Pipe Data
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Materials
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API standards
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Weights and dimensions
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Corrosion data
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Fittings
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Common pipe fittings
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Dimensions for welded fittings
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Cast steel flanged fittings.
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Forged steel screwed fittings
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Flanges
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Selection and applications
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Gasket material and selection
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Typical material on cast iron gate valve
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Split wedge
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Bolted Joints
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Torque sequencing
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Bolt type identification
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Pipe symbols
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Drafting line keys
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Branch header layout
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Threaded fasteners
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Normal thread engagement
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National pipe thread
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Normal engagement for tight joints
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British standard taper pipe thread
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Drill and tap sizes
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Non threaded fasteners
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Effects of lubricants on torque
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Bends
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Standard pipe bends
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Length of pipe in bends
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