INDUSTRIAL MAINTENANCE TECHNICAL COURSES OUTLINE

 

 

Valve Maintenance I & II 40 Hours

  1. Fundamentals

    • Classifications

    • Nomenclature

    • Valve selection guide

    • Piping definitions

    • Sealing mechanisms

    • Fluid tightness

    • Valve seating

    • Gaskets

    • Valve stem seals

  2. Valve Type Design and Construction

    • Various valve types

  3. Pressure Valves

    • Safety and Pressure relief Valves

    • Self-acting reducing Valves.

    • Check valves.

    • Foot valves

    • Valve sizing

  4. Control and Automation

    • Valve actuators

    • Control valves

    • Temperature control valves

    • Regulators

  5. Maintenance and Repair

    • Parts Manuals

    • Valve breakdown and repair

    • Troubleshooting various valves

  6. Codes and regulations

    • ASME

    • Standards

 

 

Pumps I & II - 40 Hours

  1. Pump Types

    • Terminology and Definitions

    • Positive Displacement Pumps

    • Rotodynamic pumps

    • Special Rotodynamic pumps

    • Other Pump Types

  2. Properties of Liquid

    • Terminology and Definitions

    • Water

    • Oils

    • Liquid/solids mixtures

    • Liquid/gas mixtures

    • Liquid properties

  3. Flow of Liquids

    • Fundamental equations

    • Flow losses

    • Pressure losses

    • Flow measurements

  4. Pump Theory

    • Rotodynamic pumps

    • Suction performance

    • Positive displacement pumps

  5. Piping and Pump Systems

    • Pressure drops across valves.

    • System curves

    • Multiple pumping systems

    • Water hammer

    • Pump hydraulic data.

    • Pressure pulsations

  6. Flow and Regulation Control

    • Flow regulations

    • Off-on control of constant speed pumps

    • Induction motors

    • Multispeed gearboxes

    • Throttling valves

    • Variable speed drives

  7. Strength in Materials

    • Basic materials

    • Strength and integrity

    • Material selection

  8. Seals and sealing

    • Reciprocating rods

    • Rotary shafts

    • Liquid seals

    • Process liquid seals.

    • Mechanical seals

 

Heat Exchangers

  1. Classifications of Heat Exchangers

    • Tubular

    • Shell and tube

    • Plate type

    • Extended surface

  2. Codes and Classifications

  3. Design Equations of Heat Exchangers

    • Arrangement of flow paths

    • Design equations

    • Heat transfer coefficient

  4. Heat Exchanger for the single phase

    • Heat transfer

    • Helical and spiral coils

    • Laminar forced convection

  5. Pressure drops and pumping power.

    • Tube side pressure loss

    • Pressure drops in helical and spiral coils.

    • Crossflow

  6. Double pipe heat exchangers

    • Thermal and hydraulic design

    • Design and operational features

    • Design considerations

    • Total pressure drops.

  7. Compact heat exchangers

    • Plate/fin type

    • Tube/fin type

    • Heat transfer and pressure drop.

    • Problems

  8. Shell and Tube Heat Exchangers

    • Shell type

    • Tube bundle type

    • Tube layout

    • Design criteria

    • Heat transfer and pressure drop.

  9. Heat exchanger fouling

    • Basic consideration

    • Effects on heat transfer and pressure drop.

    • Aspects of fouling

    • Controlling fouling​

  10. Gasketed plate type heat exchangers

  11. Condensers & Evaporators

  12. Storage, Installations, Operations, & Maintenance

  13. Troubleshooting

 

Diesels

  1. Introduction to Diesels

  2. Diesel Operating Principle

    • Diesel operating principles

    • Basic shop tools

    • Diesel fuel

    • Lubricants

    • Coolants

    • Bearings

    • seals

  3. Engine Components

    • Crankshafts and bearing

    • Cylinder head

    • Piston and conn rods.

    • Gear train, camshaft, engine timing

  4. Auxiliary systems

    • Lubrications

    • Cooling

    • Starting

    • Air intake and exhaust

  5. Fuel Systems

    • Components

    • Injector pumps

    • PT fuels system

    • Injection nozzles

    • Governors

  6. Electrical systems

    • Principles of the electrical system

    • Batteries

    • Ignition circuits

    • Starting circuits

    • Generator distribution

  7. Engine performance

    • Operations and maintenance

    • Testing and diagnosis

    • Tune up and adjustments.

    • Storage systems

 

 

 

Introduction to Electricity

  1. Definitions

    • Current, Voltage, Resistance

    • Resistance, Resistivity, and conductance

  2. Voltage, Current, and impedance in single phase systems

    • Alternating voltage and current

    • Inductive Reactance

    • Impedance

    • Effects of frequency on the current in a capacitor

    • Complex AC circuits

  3. AC vs DC

    • Kirchhoff’s Voltage law

    • Ohms Law

  4. Magnetic fields and magnetic forces

    • Magnetic fields

    • Mechanical forces by the interaction of magnetic fields

    • Coils, magnets, conductors

    • Behavior of ferromagnetic material’s

  5. Conductors and Insulators 

  6. Troubleshooting and emergency repair of three phase motors

    • Effects of off standard voltage and frequency on locked rotor torque

    • NEMA constraints on voltage and frequency.

    • Open phase troubleshooting

    • Locating shorted stator coil

    • Grounded stator coil

    • Squirrel cage and wound round rotor troubleshooting.

  7. Using Electrical tools for installing and testing verifications

  8. Mechanical Maintenance of Electrical Machinery

    • Maintenance of bearings

    • Maintenance of air filters

    • Disassembly of electrical motors

    • Reassemble of electrical motors.

    • Vibrations

  9. Operation and Maintenance of motor controllers

    • Basic starter circuits

    • Reading and interpret control diagrams.

    • Troubleshooting and maintenance of magnetic controllers

    • Solid-state control of motors and drives

  10. Protection against overloads and short circuits

    • Fuses

    • Testing fuses

    • Breakers

    • Interrupting rating of a breaker

    • Short circuit protection

    • Maintenance and testing of overcurrent relays and breakers.

  11. Maintenance of switchgear and other electrical apparatus

    • General switchgear maintenance

    • Overheating contacts and connectors

    • Overcurrent and fault currents

    • Visual and infrared inspections

  12. Resonance, harmonics, and their harmful effects in electrical power systems

    • Resonance in electric circuits

    • Series vs parallel resonance

 

 

Machine Alignment

  1. Introduction to mechanical Alignment

  2. Pre alignment checklist

  3. Types of alignment tools and techniques

    • Dial indicator methods

      • Rim-Face method

      • Reverse Rim Method

    • Electronic laser alignment tools

  4. Rough Alignment

  5. Correcting soft foot

  6. Pipe Strain and its effect on precision alignment

  7. Common assembly errors and its effect on precision alignment

  8. Key length calculation

  9. Thermal growth

    • Thermal growth calculation

  10. Precision Alignment

 

Principles of Machining

  1. What is machining?

  2. Speed, Feed, Depth of Cut

  3. Cutting tool material

  4. Cutting tool Geometry

  5. Cutting fluids

  6. Reference material

  7. Removing chips from the workpiece

Bearings

  1. Identify Functions of a Bearing

  2. Supports

  3. Guides and Positions

  4. Differences Between Radial and Axial Loads

  5. Radial Loads

  6. Axial Loads

  7. Common Types of Bearings

  8. Plain

  9. Metallic

  10. Nonmetallic

  11. Rolling Element

  12. Radial Ball

  13. Angular-Contact

  14. Thrust

  15. Cylindrical Roller

  16. Needle Roller

  17. Cam-Type and Load-Following

  18. Spherical Roller

  19. Tapered Roller

  20. Linear Bearings

  21. Mounted Bearings

  22. Pillow Block

  23. Take Up

  24. Flange

  25. Bearing installation and Maintenance

 

Compressor I & II

  1. Positive Displacement Compressor

    • Reciprocating Compressors

    • Major components

    • Compressor comparison reciprocating and centrifugal.

    • Considerations for upstream separators

  2. Rotary Compressors

    • Helical Screw Compressors

    • Operating principle and construction

    • Screw compressor staging

    • Oil free vs flooded twin screw compressors.

  3. Centrifugal Gas Compressors       

    • Where they are used

    • Configurations and components

  4. Compressor power transmission

    • Coupling configurations

    • Bearing configuration

  5. Compressor Performance

    • Surge control

    • Flow coefficient

    • Process efficiencies

    • Throughput control

  6. Testing of compressors

    • ASME power test code

    • Types of performance tests

  7. Applications considerations

    1. Natural gas

    2. Steel industry

    3. Offshore industry

    4. Industrial industry

    5. Petrochemical industry

 

Pipe, Fittings, and Auxiliaries I & II

  1. Definitions

  2. Pipe Data

    • Materials

    • API standards

    • Weights and dimensions

    • Corrosion data

  3. Fittings

    • Common pipe fittings

    • Dimensions for welded fittings

    • Cast steel flanged fittings.

    • Forged steel screwed fittings

  4. Flanges

    • Selection and applications

    • Gasket material and selection

    • Typical material on cast iron gate valve

    • Split wedge

  5. Bolted Joints

    • Torque sequencing

    • Bolt type identification

  6. Pipe symbols

    • Drafting line keys

    • Branch header layout

  7. Threaded fasteners

    • Normal thread engagement

    • National pipe thread

    • Normal engagement for tight joints

    • British standard taper pipe thread

    • Drill and tap sizes

  8. Non threaded fasteners

  9. Effects of lubricants on torque

  10. Bends

    • Standard pipe bends

    • Length of pipe in bends