Industrial Mechanic (Millwright) Level 3

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1 Industrial Mechanic (Millwright) Level 3 Rev. September 2005

2 Industrial Mechanic (Millwright) Unit: G5 Prime Movers I Diesel 1 Level: Duration: Three 60 hours Theory: 20 hours Practical: 40 hours Overview: This unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to understand the operation of internal combustion engines, turbines and electric motors in compliance with safety procedures. Material covered includes: Internal combustion engines Percent of Objectives and Content: Unit Mark (%) 1. Describe the principles of operation of an internal combustion engine: 25% a. 4 stroke cycle engines principles for gas and diesel engines b. 2 stroke cycle engines principles for gas and diesel engines c. Differences between 2 stroke and 4 stroke engines d. Differences between gas and diesel engines e. Fuel injection f. Lubrication methods 2. Describe the internal parts and list their functions: 25% a. Crankshaft b. Main bearings c. Flywheels d. Cylinder head e. Camshafts, lifters and pushrods f. Engine block g. Pistons, rings and connecting rods h. Valve trains i. Natural aspiration j. Turbo-chargers k. Superchargers l. Glow plug m. Injectors n. Governors 3. Describe the principles of operation for diesel engines: 25% a. Compression ignition b. Fuel injection c. Turbochargers and superchargers 4. Disassemble, inspect and troubleshoot engine components 50% *** 1 Rev. September 2005

3 Industrial Mechanic (Millwright) Unit: H1 Hydraulics I Level: Duration: Three 115 hours Theory: 70 hours Practical: 45 hours Overview: This unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to maintain hydraulics systems. It also provides the apprentice with the knowledge and skills necessary to maintain non-positive displacement pumps and positive displacement pumps. It also provides the apprentice with the knowledge and skill necessary to install and maintain pipes and piping assembly related to industrial Mechanic (Millwright). Material covered includes: Safety Centrifugal pumps and their components Start up and shut down procedures Threading procedures Tubing, valves and fittings Physical laws and principles Hydraulic formulas Schematics Parts, components and accessories Percent of Objectives and Content: Unit Mark (%) 1. Identify and describe the parts of non-positive displacement pumps and their function. 5% a. Casing styles b. Impeller styles c. Stuffing box d. Packing e. Mechanical seals f. Shaft sleeves g. Packing glands h. Wear rings and plates 2. Identify the installation of non-positive displacement pumps. 5% 3. Describe the principles of operation of non-positive displacement pumps. 5% a. Non-positive displacement pump theory b. Pump types and their use c. Centrifugal and axial flow d. Terms and definitions e. Volute and diffuser pumps f. Multi-stage pumps and their purpose 4. Define the different terms associated with the operation of the pump. 5% a. Pump head b. Suction head 2 Rev. September 2005

4 c. Suction lift d. Velocity head e. Capacity, rating and size 5. Describe problems encountered with pumps. 5% a. Vapour binding b. Cavitation c. Failure to deliver product d. Reduced capacity or pressure e. Pump vibration f. Casing Wear/damage g. Excessive packing wear h. Internal and external sealing 6. Describe procedures to disassemble, inspect, repair and reassemble non-positive displacement pumps. 5% a. Pump isolation and lock out b. Pump casings c. Impeller design and mounting d. Wear rings and plates e. Hydraulic balancing devices f. Seals and packing g. Bearings 7. Describe the principles of operation of a positive displacement pump. 5% a. Describe the principles of operation of a positive displacement pump: Theory of operation of positive displacement pumps Classification and uses of positive displacement pumps Volumetric efficiency Positive displacement Variable displacement Pressure, volume, velocity Pressure compensation Valve operation b. Describe the different types of positive displacement pumps: Plunger and piston pumps Diaphragm pumps Axial and radial piston pumps Gear and vane pumps c. Identify parts of the pump and state their function Packing and seals d. Follow proper maintenance procedures for positive displacement pumps: Dismantling procedures Visual inspection Packing procedures 8. Identify various types of pipe and tube fittings and their uses. 5% a. Pressure ratings for valves and fittings b. Pipe and tubing fittings and joints 9. Describe procedures to cut, thread and assemble pipe and tubing. 5% a. Pipe sizing methods b. Pipe hangers and supports c. Cutting, reaming and threading pipe d. Cutting fluids e. Pipe thread sealants f. Tubing and tube fittings 10. Identify various types and uses of valves and describe maintenance procedures. 5% a. Identification of codes on valves and fittings b. Gate valves 3 Rev. September 2005

5 c. Globe valves d. Check valves e. Needle valves f. Relief valves g. Low pressure steam control valve h. Ball valve i. Butterfly valve 11. Describe Pascal s Law. 10% a. Pressure b. Force c. Area d. Work and power e. Horsepower and torque 12. Describe Bernoulli s Principle. 10% a. Velocity b. Pressure drop and flow 13. Solve problems using hydraulic formulas. 10% a. Force, pressure and area formula b. Cylinder rod speed formula c. Sizing hydraulic reservoirs d. Sizing of hydraulic pumps 14. Describe the operation and purpose of valves used in hydraulic systems. 10% a. Directional control valves b. Pressure control valves c. Volume (flow) control valves 15. Describe the operation of components used in hydraulic systems and safety considerations required. 10% a. Reservoirs b. Hydraulic fluid c. Piping and sealing d. Pumps e. Cylinders f. Filters and strainers g. Motors h. Accumulators i. Intensifiers j. Pressure switches k. Hydraulic hose and fittings l. Pipe and tubing m. Solenoids n. Valves 16. Identify the components needed to make up a basic hydraulic system. 10% 17. Identify various components of a system on a schematic. 10% *** 4 Rev. September 2005

6 Industrial Mechanic (Millwright) Unit: Level: Duration: H3 Pneumatics I Three 85 hours Theory: 40 hours Practical: 45 hours Overview: This unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to install and maintain pneumatic systems and in compliance with safety procedures. In addition, this unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to maintain dynamic and positive displacement compressors and vacuum systems. Material covered includes: Physic s laws and principles Schematics Operation of pneumatic systems, components, parts and accessories Principle of operation Gas laws Pressure control Percent of Objectives and Content: Unit Mark (%) 1. Describe gas laws as they pertain to pneumatics. 20% a. Atmospheric pressure b. Gauge and absolute pressure c. Force, pressure, area d. Boyle s Law e. Charles s Law f. Gay-Lussac s Law g. Ideal Gas Law 2. Classify the various components of a system by the functions they perform. 10% a. Compressors b. Pressure control valves c. Directional control valves Packed bore and sliding spool d. Volume flow control valves Quick exhaust and shuttle valves e. Filters f. Lubricators g. Regulators h. Coolers and heat exchanger i. Receivers j. Dryers k. Pressure relief valves l. Muffler m. Actuators n. Cylinder cushions 5 Rev. September 2005

7 3. Determine the series of operation of a system from a schematic. 10% a. Schematics b. Symbols c. Schematic development 4. Describe the principles of operation of reciprocating and rotary compressors. 10% a. Reciprocating compressors and access b. Rotary compressors c. Screw compressors d. Vane e. Diaphragm f. Wet screw g. Dry screw 5. Identify gas laws and apply them to compressors. 20% a. Boyle s Law b. Charles s Law c. Gay-Lussac s Law d. Ideal Gas Law 6. Identify and describe the parts and accessories for compressors. 10% a. Regulators b. Lubricators c. Filters d. Receivers e. Valves f. Pistons g. Connecting rods h. Crankshafts i. Rotors j. Vanes k. Crossheads l. Cylinders m. Maximum pressure control devices n. Pressure relief valve on receiver o. Piping control lines 7. Describe methods of pressure control on a compressor. 10% a. Unloading devices b. Stop start method c. Throttling intake d. Variable speed drives e. Atmospheric pressure Vacuum pressure 8. Describe maintenance procedures for compressors. 10% a. Air treatment b. Separators c. Lubrication methods d. Intercooolers e. After coolers f. Receivers g. Air dryers h. Regulators i. Lubricators *** 6 Rev. September 2005

8 Industrial Mechanic (Millwright) Unit: Level: Duration: H5 Electrical Controls Three 20 hours Theory: 20 hours Practical: 0 hours Overview: This unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to understand the principles of electricity encountered as an Industrial Mechanic (Millwright). This unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary for electrical systems diagnosis as it applies to the trade of Industrial Mechanic (Millwright) and in compliance with safety procedures. This unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to work with programmable logic controllers. The content of the electrical section of this unit is not to suggest that a Journey person Millwright should complete the tasks normally performed by a Journey person Electrician. The intent is to provide the Millwright with enough knowledge so that safe decisions may be made when working on or around electrical equipment. Material covered includes: Compliance with safety procedures Electrical terminology Direct and alternating current Electrical circuits Electrical motors Abbreviations and symbols Electrical Controls Programmable Logic Controllers (PLCs) Percent of Objectives and Content: Unit Mark (%) 1. Identify basics of electricity as appropriate to complete various tasks as pertains to trade of Industrial Mechanic (Millwright) and Electrical. 40% 2. Identify safety procedures when working around electrical equipment. a. Lockout and tag-out procedures Reasons for safe lock-out and tag-out of electrical controls Rules and procedures for safe lock-out and tag-out of electrical controls b. Breakers and switches c. Personal safety d. Electrical awareness Warning signs of potential electrical hazard Procedures to be followed to prevent personal injury e. Fusible links and heaters 7 Rev. September 2005

9 3. Describe the basic principles of electricity. a. Volts b. Amperage c. Resistance d. Watts e. Test meters Types Applications f. Purpose of breakers, fusible links, heaters and switches including breaker re-setting procedures g. Types of test meters and their uses 4. Describe electron theory, Ohm s Law and associated formulae. 5. Describe magnetism. a. Basic magnetic applications b. Permanent c. Electro 6. Describe electrical terminology. a. Colomb b. Voltage c. Current d. Ampere e. Resistance f. ohm 7. Describe what is meant by resistance and the factors affecting it. 8. Describe the characteristics of conductors and insulators and their applications. 9. Describe electromagnetism and how it can be used to produce voltage. 10. Qualified electricians should be working on energized equipment. 11. Identify cycles. a. 60 cycle system b. 50 cycle system 12. Identify phases. a. Single phase b. Three phase 13. Describe electrical circuits and schematics, their components and operation. a. Open/closed circuits 14. Identify and read electrical schematic. a. Basic information contained on simple schematics b. Purpose of schematics c. Testing Line voltage Load amperage Line resistance Interlocks and open circuits 15. Describe wiring systems. a. Two wire b. Three wire c. Colour codes d. Wire sizing e. Electrical codes 8 Rev. September 2005

10 16. Describe the procedure used to construct electric circuits. a. Series b. Parallel c. Series-parallel 17. Describe overload protection circuits. 18. Interpret the abbreviations, formula symbols and circuit symbols found in circuit diagrams. 19. Describe the parts and operating principles of electric motors. 20. Describe the safe removal and reinstallation of electrical motors. a. Types of fuses. b. Types of breakers. c. Maintenance and servicing of electric motors in shop 21. Describe the procedures used for troubleshooting and repair of electric motors. a. Safe removal of electric motors b. Electric motor maintenance mechanical procedures c. Interpretation of data contained on electric motor nameplates 22. Identify basics of Electrical Controls. 30% 23. Explain electrical systems diagnosis as it applies to the trade. 24. Identify simple circuits from wiring diagrams. 25. Trace simple circuits from wiring diagrams. 26. Identify the appropriate test meter to take readings. a. Ampere b. Volt c. Ohm 27. Identify basics of Programmable Logic Controllers (PLCs). 30% 28. Identify basic components. a. Power supplies: Central Processor I / O Modules b. Central Processing Unit: Processor Types Memory: -Executive -User -I / O Status memory Communication c. I/O section: Descrete Analog Specialty d. Programming devices: Handheld Dedicated computer Personal computer e. Peripherals: Printers Communications 9 Rev. September 2005

11 29. Identify Input / Output Section. a. Types and basic operating principles: Optical isolation b. Discrete and analog modules: c. Wiring methods: Bonding methods 30. Identify I / O Configuration. a. Local: Fixed I / O Modular I / O b. Remote: Distributed I / O Distributed Control Systems (DCS) 31. Identify and explain using ladder diagrams. a. Programming relay type instructions: System configuration Address locations: -External addresses -Internal addresses Documentation methods b. Programming discrete inputs: Examine On Examine Off Transitional contacts c. Programming outputs: Discrete outputs Logical / internal outputs Latching relay / instructions Interposing relays d. Timers: Address locations Preset and accumulated times Time On and Time Off timers Cascading e. Counters: Address locations Preset and accumulated count Count up and count down counters 32. Identify programming considerations. a. Memory limitations b. Networks c. Program Scan d. Nesting 33. Safe programming and wiring considerations. a. Security Key locks Software b. Maser Control Relay c. Stop and Emergency Stop Push Buttons d. Program Documentation 34. Identify Analog I / O. a. Analog I / O: Analog inputs Analog outputs Transducers b. Voltage and current sensing modules: 10 Rev. September 2005

12 c. Resolution / Scaling: Binary conversion d. Conductor bonding methods 35. Explain troubleshooting. a. Bonding connections: Low and extra low voltage systems b. Controller self diagnostics: LED indicators Watch Dog Timer c. Trouble shooting power supplies: Controller I / O modules d. Trouble shooting discrete modules: Over current protection LED indicators e. Search Functions: f. Force / Disable functions: Inputs Outputs Internal relays/contacts *** 11 Rev. September 2005

CURRICULUM BOSCH-REXROTH (CENTRE OF EXCELLENCE) GANPAT UNIVERSITY

ANNEXURE - A CURRICULUM BOSCH-REXROTH (CENTRE OF EXCELLENCE) Host Institute: GANPAT UNIVERSITY Contents of Basic Industrial Pneumatics -----------------------------------------------------------------------------------------------------------------