IMT- COURSE OUTLINE | Hendrix2020

INDUSTRIAL MAINTENANCE TECHNICAL COURSES OUTLINE

Valve Maintenance I & II - 40 Hours

Fundamentals
- Classifications
- Nomenclature
- Valve selection guide
- Piping definitions
- Sealing mechanisms
- Fluid tightness
- Valve seating
- Gaskets
- Valve stem seals
Valve Type Design and Construction
- Various valve types
Pressure Valves
- Safety and Pressure relief Valves
- Self-acting reducing Valves.
- Check valves.
- Foot valves
- Valve sizing
Control and Automation
- Valve actuators
- Control valves
- Temperature control valves
- Regulators
Maintenance and Repair
- Parts Manuals
- Valve breakdown and repair
- Troubleshooting various valves
Codes and regulations
- ASME
- Standards

Pumps I & II - 40 Hours

Pump Types
- Terminology and Definitions
- Positive Displacement Pumps
- Rotodynamic pumps
- Special Rotodynamic pumps
- Other Pump Types
Properties of Liquid
- Terminology and Definitions
- Water
- Oils
- Liquid/solids mixtures
- Liquid/gas mixtures
- Liquid properties
Flow of Liquids
- Fundamental equations
- Flow losses
- Pressure losses
- Flow measurements
Pump Theory
- Rotodynamic pumps
- Suction performance
- Positive displacement pumps
Piping and Pump Systems
- Pressure drops across valves.
- System curves
- Multiple pumping systems
- Water hammer
- Pump hydraulic data.
- Pressure pulsations
Flow and Regulation Control
- Flow regulations
- Off-on control of constant speed pumps
- Induction motors
- Multispeed gearboxes
- Throttling valves
- Variable speed drives
Strength in Materials
- Basic materials
- Strength and integrity
- Material selection
Seals and sealing
- Reciprocating rods
- Rotary shafts
- Liquid seals
- Process liquid seals.
- Mechanical seals

Heat Exchangers

Classifications of Heat Exchangers
- Tubular
- Shell and tube
- Plate type
- Extended surface
Codes and Classifications
Design Equations of Heat Exchangers
- Arrangement of flow paths
- Design equations
- Heat transfer coefficient
Heat Exchanger for the single phase
- Heat transfer
- Helical and spiral coils
- Laminar forced convection
Pressure drops and pumping power.
- Tube side pressure loss
- Pressure drops in helical and spiral coils.
- Crossflow
Double pipe heat exchangers
- Thermal and hydraulic design
- Design and operational features
- Design considerations
- Total pressure drops.
Compact heat exchangers
- Plate/fin type
- Tube/fin type
- Heat transfer and pressure drop.
- Problems
Shell and Tube Heat Exchangers
- Shell type
- Tube bundle type
- Tube layout
- Design criteria
- Heat transfer and pressure drop.
Heat exchanger fouling
- Basic consideration
- Effects on heat transfer and pressure drop.
- Aspects of fouling
- Controlling fouling
Gasketed plate type heat exchangers
Condensers & Evaporators
Storage, Installations, Operations, & Maintenance
Troubleshooting

Diesels

Introduction to Diesels
Diesel Operating Principle
- Diesel operating principles
- Basic shop tools
- Diesel fuel
- Lubricants
- Coolants
- Bearings
- seals
Engine Components
- Crankshafts and bearing
- Cylinder head
- Piston and conn rods.
- Gear train, camshaft, engine timing
Auxiliary systems
- Lubrications
- Cooling
- Starting
- Air intake and exhaust
Fuel Systems
- Components
- Injector pumps
- PT fuels system
- Injection nozzles
- Governors
Electrical systems
- Principles of the electrical system
- Batteries
- Ignition circuits
- Starting circuits
- Generator distribution
Engine performance
- Operations and maintenance
- Testing and diagnosis
- Tune up and adjustments.
- Storage systems

Introduction to Electricity

Definitions
- Current, Voltage, Resistance
- Resistance, Resistivity, and conductance
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
AC vs DC
- Kirchhoff’s Voltage law
- Ohms Law
Magnetic fields and magnetic forces
- Magnetic fields
- Mechanical forces by the interaction of magnetic fields
- Coils, magnets, conductors
- Behavior of ferromagnetic material’s
Conductors and Insulators
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.
Using Electrical tools for installing and testing verifications
Mechanical Maintenance of Electrical Machinery
- Maintenance of bearings
- Maintenance of air filters
- Disassembly of electrical motors
- Reassemble of electrical motors.
- Vibrations
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
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.
Maintenance of switchgear and other electrical apparatus
- General switchgear maintenance
- Overheating contacts and connectors
- Overcurrent and fault currents
- Visual and infrared inspections
Resonance, harmonics, and their harmful effects in electrical power systems
- Resonance in electric circuits
- Series vs parallel resonance

Machine Alignment

Introduction to mechanical Alignment
Pre alignment checklist
Types of alignment tools and techniques
- Dial indicator methods
  - Rim-Face method
  - Reverse Rim Method
- Electronic laser alignment tools
Rough Alignment
Correcting soft foot
Pipe Strain and its effect on precision alignment
Common assembly errors and its effect on precision alignment
Key length calculation
Thermal growth
- Thermal growth calculation
Precision Alignment

Principles of Machining

What is machining?
Speed, Feed, Depth of Cut
Cutting tool material
Cutting tool Geometry
Cutting fluids
Reference material
Removing chips from the workpiece

Bearings

Identify Functions of a Bearing
Supports
Guides and Positions
Differences Between Radial and Axial Loads
Radial Loads
Axial Loads
Common Types of Bearings
Plain
Metallic
Nonmetallic
Rolling Element
Radial Ball
Angular-Contact
Thrust
Cylindrical Roller
Needle Roller
Cam-Type and Load-Following
Spherical Roller
Tapered Roller
Linear Bearings
Mounted Bearings
Pillow Block
Take Up
Flange
Bearing installation and Maintenance

Compressor I & II

Positive Displacement Compressor
- Reciprocating Compressors
- Major components
- Compressor comparison reciprocating and centrifugal.
- Considerations for upstream separators
Rotary Compressors
- Helical Screw Compressors
- Operating principle and construction
- Screw compressor staging
- Oil free vs flooded twin screw compressors.
Centrifugal Gas Compressors
- Where they are used
- Configurations and components
Compressor power transmission
- Coupling configurations
- Bearing configuration
Compressor Performance
- Surge control
- Flow coefficient
- Process efficiencies
- Throughput control
Testing of compressors
- ASME power test code
- Types of performance tests
Applications considerations
1. Natural gas
2. Steel industry
3. Offshore industry
4. Industrial industry
5. Petrochemical industry

Pipe, Fittings, and Auxiliaries I & II

Definitions
Pipe Data
- Materials
- API standards
- Weights and dimensions
- Corrosion data
Fittings
- Common pipe fittings
- Dimensions for welded fittings
- Cast steel flanged fittings.
- Forged steel screwed fittings
Flanges
- Selection and applications
- Gasket material and selection
- Typical material on cast iron gate valve
- Split wedge
Bolted Joints
- Torque sequencing
- Bolt type identification
Pipe symbols
- Drafting line keys
- Branch header layout
Threaded fasteners
- Normal thread engagement
- National pipe thread
- Normal engagement for tight joints
- British standard taper pipe thread
- Drill and tap sizes
Non threaded fasteners
Effects of lubricants on torque
Bends
- Standard pipe bends
- Length of pipe in bends

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