Course Details
- Course Code: OS-TT-M101-S-14M
- Mode of Delivery: Onsite
- Duration: 14 Months
- Price: On Request
Mechanical Maintenance
Course Overview
The programme starts with an induction to the course and training facilities to fully understand the training process and requirements. This course is delivered through Instructor-led training and Workshop based practical training with various assessments to ensure that the candidate achieves theoretical and practical competencies. Upon successful completion, the candidates will gain the skills and knowledge necessary to perform maintenance on mechanical equipment safely.
This course is for anyone interested in doing activities linked with the employment of an engineering operative.
The entry prerequisites are a good attitude toward learning, a solid motivation to study, and a reasonable level of language proficiency.
Candidates on successful completion of training are entitled to a ‘Certificate of Attendance’ attested by the Ministry of Higher Education, Research and Innovation from NTI and a National Vocational Qualification Certificate (NVQ) from Excellence, Achievement and Learning (EAL), UK.
Other Details
Module 1: Mechanical Safety
- Health safety and the law
- Employers’ responsibilities
- Employees’ responsibilities
- Electrical hazards
- Fire fighting
- Fire precautions and prevention
- Accidents
- First aid
- Personal protection
- Hazards in the workplace
- Manual lifting
- Mechanical lifting equipment
- Use of lifting equipment
- Material Safety Data Sheets (MSDSs)
- Equipment Maintenance
- Risk assessment & Control measures
- HASAWA/RD ……../MD……..
- Toolbox talk, Safe card
- Incident reporting/ Hot work/COSHH
Module 2: Work Planning
- Job planning
- Drawing interpretation
- Job card
- Tools & materials request
- Housekeeping
- Store issue/return
- Upkeep and maintenance/Workshop inspection
- Continual improvement
- Personal development plan
- Working relationships
- Time management
- Conflict resolution
- Cultural awareness
- Seeking Guidance and support
- Team roles and effective team working
Module 3: Machine tools
- Engineering drawing (introduction)
- Methods of record keeping
- Various sources for technical information, relevant standards
- Sliding mechanism in machine tools
- Power transmission system like Flat belt drive, Vee belt drive, Gear drive -Spur, Helical, Spiral, Rack and Pinion, Bevel ,Worm and Worm wheel
- Types of bearings
- Maintenance activities on Drilling machine, lathe machine, milling machine, surface, cylindrical, centerless grinding machine
Module 4: Compressors
- Positive Displacement Compressors
- Dynamic Compressors
- Reciprocating Compressor
- Rotary Compressor
- Centrifugal Compressor
- Axial Compressor
- Natural Air Cooling
- Forced Air Cooling
- Water cooling
- Closed Lube Oil Systems
- Seals & Seal oil/gas Systems
- Dry Gas Seal Systems
- Seal Gas Systems
- Labyrinth Seals
- Carbon Ring Seals
- Maintenance activities on compressors
Module 5: Hydraulics and Pneumatics
- Basic Principles of hydraulics
- Basic components in Hydraulic systems
- Directional control valves in Hydraulic system
- Cylinders
- Schematic diagram in Hydraulic system
- Basic principle of Pneumatic
- Basic components in Pneumatic systems
- Directional control valves in Pneumatic system
- Execute the circuit diagrams using Hydraulic components
- Analyze the problems for noise, high temperature and slow operation in the hydraulic system
- Check the Parameter for clogged filter, oil level and viscosity, speed of the motor, pressure, noisy pump, proper pipe and tube fitting.
- Execute the different Circuit diagram using Pneumatic components.
- Analyze the reason for like pressure loss, leaks, over pressurization and overheating
- Check on actuator for slow movement, less pressure, FRL unit, DCV not changing, Drift in air cylinder, contamination in circuit.
- Identify Common causes in pneumatic and hydraulic system
- Follow the relevant start up maintenance procedures
- Disassemble the Directional control valve, cylinders and actuators as per service guide for pneumatic and hydraulic system
- Identify and inspect the parts
- Replace the parts if necessary
- Reassemble the cylinders, directional control valves and actuators as per service guide for pneumatic and hydraulic system.
- Follow the relevant shut down procedures
Module 6: Pumps
- Introduction to Pumps
- Dynamic pumps:(Centrifugal pumps)
- Based on directions of flow -Radial flow, Axial flow and Mixed flow
- Based on suction type (Single type and double type)
- Based on Mechanical construction (Closed Type, Open Type and Semi Open or Vortex Type)
- Vertical Pumps- Line shaft pumps, submersible pumps and horizontally mounted axial mounted pumps
- Displacement pumps:
- Reciprocating pumps – Piston, Plunger and Diaphragm type
- Rotary pumps-Single rotor and multi rotor.
- Impellers
- couplings
- Seals
- Bearings
- Casing
- Head
- Head loss
- Cavitation and priming
- Net Positive Suction Head (NPSH)
- Affinity laws
- Disassemble the dynamic pumps (Centrifugal and vertical pumps) as per service guide.
- Identify and inspect the parts
- Replace the components if necessary
- Reassemble the Pumps.
- Check for Sufficient pressure, discharge, no losses while priming, no leakage in stuffing box, input power, vibration and overheat
- Disassemble the Displacement (Reciprocating and gear pumps) as per service guide.
- Identify and inspect the parts
- Replace the components if necessary
- Reassemble the pumps as per service guide.
- Check for Sufficient pressure, discharge, no losses while priming, no leakage in seals and valves, input power, vibration and overheat
- In cooperate the pump in the system to analyze its efficiency.
Module 7: Valve and actuators
- Introduction to valve and actuators
- Linear Motion Control Valves:
- Gate valve
- Globe valve (Single seated and double seated)
- Diaphragm valve
- Rotary Motion Control Valves:
- Ball valve
- Butterfly valve
- Disc Valve
- Gaskets
- O Ring
- Circlip
- Cotter pin
- Cotter pin bolts
- Circlip bolts
- Spacer and nuts
- Gland packing:
- Procedure for Gland packing
- Gasket:
- Procedure for gasket installation
- Stud fastening procedure
- Manual actuators:
- Introduction
- Hand wheel
- Chain wheel
- Gears
- Rotary vane
- Pneumatic actuators:
- Spring/Diaphragm
- Piston
- Hydraulic actuators:
- Working principle of hydraulic actuator
- Electrical actuators:
- Linear electric actuator
- Rotary electric regulating type actuator
- Disassemble the linear control valve (Gate and Globe valve) as per service guide.
- Identify and inspect the parts
- Replace the components if necessary
- Reassemble the valves.
- Check for leakage between valves, bonnet leakage, valve body cavity leakage, leakage at the valve seat plate
- Disassemble the Rotary control valve (Ball valve) as per service guide.
- Identify and inspect the parts
- Replace the components if necessary
- Check for valve ball overturned, the valve sealing surface is crushed, no pre tightening pressure on the sealing surface, contact surface between ball valve seat and body
- Reassemble the valves as per service guide.
- Follow the relevant startup procedure
- In cooperate the control valves in the system and conduct the leak and performance test as per service guide
Module 8: Maintenance Planning and scheduling
- Maintenance Planning and scheduling
- Describe maintenance planning
- Describe maintenance scheduling
- Advantages of maintenance planning and scheduling
- Disadvantages of maintenance planning and scheduling
- Importance of maintenance planning and scheduling
- Maintenance planning principles
- Protect planner
- Focus on future work
- Component level files
- Use planner judgment from time estimates
- Recognize the skills of technicians
- Measure performance with work sampling
- Maintenance scheduling principles
- Importance of schedules and job priorities
- Schedule based on the projected highest skills available
- Schedule for every available work hour
- Benefits of maintenance planning
- Budgeting by controlling resources associated with maintenance
- Reduction in equipment down time
- Reduction in spare parts
- Improved workflow
- Improving efficiency by controlling the movement of resources
- Maintenance planning tools
- Work order systems
- Equipment history and data
- Maintenance metrics
- Maintenance planning techniques
- Selection of maintenance planner
- Train the planner
- Understand the difference between planning and scheduling
- Ensuring job plans are clear and concise
- Provide feedback on completed task
- Make changes based on feedback
- Equipment maintenance planning
- Introduction to equipment maintenance
- Resources required in equipment maintenance planning
- Money resources
- Material resources
- Human resources
- Various levels of maintenance scheduling
- Long term master schedule
- Weekly schedule
- Daily schedule
- Effective scheduling
- Implementation of maintenance planning and schedule
- Phase 1 – Set up
- Phase 2 – Define and analyze the situation
- Phase 3 - Develop and prepare for delivery
- Phase 4 – Implement
- Phase 5 – Review
- Phase 6 – Sustain
- Maintenance scheduling techniques
- Bar chart
- Gantt chart
- Preparing a maintenance schedule.
- Prepare a maintenance schedule for a car
- Prepare maintenance schedule for a hydraulic press machine
- Prepare maintenance schedule for a drilling machine
By the end of the module the candidate will be able to:
- Identify and deal with the health and safety at work
- Select appropriate personal protective equipment
- Familiarize with the basic engineering hand tools, their uses and application in an engineering environment
- Conduct risk assessment for mechanical maintenance activities
- Read and interpret mechanical drawings
- List the types of maintenance
- Identify the different types of machine tools used in industry
- Identify and carry out the maintenance activities on machine tools
- Assemble the power transmission using (flat belt drive, vee belt drive, gear drive-spur, helical, spiral worm and worm wheel)
- Distinguish the types compressors
- Explain the principles of operation of the compressors and associated equipment
- Identify and locate the basic maintenance procedures
- State the use of dry gas seals including component parts, mode of operation, common symptoms, causes of failure encountered on the system and associated symptoms
- List the maintenance techniques used for Compressors
- Describe basic principles in hydraulic and pneumatic system.
- Identify major components used in hydraulic and pneumatic system.
- Write the most important properties of hydraulic fluids.
- Recognize symbols used to represent in the hydraulic and pneumatic system.
- Select appropriate valves and actuators.
- Sketch the schematic diagram for pneumatic and hydraulics.
- Determine the common hydraulics problems and its root cause.
- Choose the most common faults in hydraulic and pneumatic system
- Differentiate and classify the types of pumps.
- State the working principles of dynamic and positive displacement pumps.
- Label the components and the accessories used in pumps.
- List the uses of impeller, coupling, seals, bearings and casing.
- Describe the terms discharge, Displacement, head, total head, head loss, cavitation, NPSH and priming.
- Solve problems on pump affinity laws to check the efficiency of pumps.
- Locate the basic maintenance procedures in pumps
- State the most common faults in pumps
- Mention the common term used in valve and actuator.
- Distinguish and classify types of valves and actuator, its working principles, components and accessories used.
- Outline the use of seals, gland packing including component parts.
- Recognize the basic maintenance procedures.
- Recite the most common faults in various machine tools, compressors, hydraulic and pneumatic system, pumps, valve and Actuators.
- Write the parameters to be monitored in service to assure performance, relevant start-up and shut down procedures of various machine tools, compressors, hydraulic and pneumatic system, pumps, valve and Actuators.
- Enumerate maintenance planning, maintenance scheduling principles, its advantages and disadvantages and maintenance scheduling procedures
- Choose the maintenance planning tools, maintenance and planning techniques and resources required in equipment maintenance planning
- Discuss effective scheduling, levels of maintenance scheduling, its techniques and implementation.
Instructor-Led Onsite Training