MECHANICAL AND ELECTRICAL SEMINARS

Transcription

1 INDUSTRIAL TRAINERS OF AMERICA, INC COURSE CATALOG MECHANICAL AND ELECTRICAL SEMINARS Hands-on Training Mechanical Skills Training Electrical Skills Training Fluid Power Training HVAC Training EPA Certification

2 Table of Contents Mechanical Training Seminars Page M400 Achieving Excellence in Maintenance Management 5 M401 Environmental Compliance 5 M402 Confined Space Entry 6 M500 Basic Shop Math Refresher 6 M501 Mechanical Troubleshooting Techniques 7 M502 Bearings 8 M503 Lubrication 8 M504 Mechanical Drives 9 M505 Precision Alignment 10 M506 Centrifugal Pumps and Sealing Methods 11 M507 Fans and Blowers 12 M508 Vibration Analysis 12 M509 Air Compressors 13 M510 Precision Measurement 13 M511 HVAC 14 M512 AC&R 15 M513 EPA Exam Preparatory Course 16 M514 Boilers 16 M515 Welding 17 M516 Pneumatics 18 M517 Hydraulics 18 M518 Pipefitting 19 Electrical Training Seminars Page E600 Electrical Troubleshooting Techniques E601 Motor Controls and Trouble-shooting 21 E602 Ladder Diagrams 22 E603 Grounding and Bonding 22 E604 AC Motors 22 E605 AC Motor Controls 22 E606 Industrial Electricity Basics 23 E607 Electrical Safety 24 E608 PLC Basics 25 E609 Variable Frequency Drive Basics 25 E610 Electrical Systems/Transformers 25 E611 Cross-Craft Industrial Electricity 25 E NEC National Electrical Code 25 E613 Instrumentation Measurement and Control Basics 26 E NFPA 70E Arc Flash 27 2

3 ABOUT OUR COMPANY Services Industrial Trainers of America, Inc. offers hands-on, on-site, industrial maintenance mechanical technical training seminars, electrical technical training seminars, safety training seminars, compliance training seminars, compliance programs, and continuous improvement programs that serve industrial plant and facilities maintenance management and maintenance personnel. We also offer consulting services, as well as custom training and course development, so that together we can improve the operation of your plant or facility. Benefits Effective Industrial Training and Consulting! Safer Work Environment Compliance with Standards and Codes Improved Technical Skills Increased Efficiency Reduced Operating Costs Our instructors are "been there, done that" people. Real life experience brings our training alive to our students. Pre-tests and Post-tests are available upon request. You can track progress. Training completed in a short amount of time that keeps reaping rewards long into the future. Students acquire a new appreciation for working safely alone & with others. Everyone gains a heightened awareness of potential hazards that anyone may come into contact with for any reason. 3

4 ndustrial Trainers of America, Inc. is a flexible company. We understand scheduling difficulties, shift coverage, budget constraints, and many other challenges that need to be addressed in order to accomplish your training goals. hank you for your interest in our training company. We look forward to serving you! sk us about how we can save you time and money by combining related topics into combination seminars! 4

5 M400 Achieving Excellence in Maintenance Management The purpose of this seminar is to present the maintenance professional with a solid resource of information that will enable him or her to better manage, maintain, and improve the operation of their plant or facility through the effective and efficient use of their maintenance department resources, both human and material. Some of the key topics covered are: v The process of effective and efficient Management v The art of being a successful Leader v The 10 Keys to a successful Maintenance department v Proper and effective Preventive Maintenance programs v How to Optimize PM efforts, and measure their effectiveness. v Predictive Maintenance programs, how and when to use this technique. v Computerized Maintenance Management Systems, how to choose and use. v Storerooms that make cents v Realistic budgeting, the use of Contractors and much, much more! M401 Environmental Compliance This general course heading includes training from Asbestos and Lead, to OSHA regulations regarding Hazardous Waste. A variety of subjects include: v OSHA Hazardous Waste Training v Lead Abatement v Asbestos Handling 5

6 M402 Confined Space Entry This course covers the OSHA guidelines for confined space entry safety. Some of the key topics covered are: v Hazards v Types of Confined Spaces v Reasons for Entering Confined Spaces v Flammable Atmospheres v Toxic Atmospheres v Irritant (Corrosive) Atmospheres v Asphyxiating Atmospheres v General Safety Hazards Mechanical Communication Problems Entry and Exit v Physical Hazards Thermal Effects Noise Vibration v General/Physical Scaffolding Surface Residues Structural Hazards M500 Basic Shop Math Refresher This course is designed to refresh the student s math skills, so that they can perform calculations related to maintenance in industry. Some of the topics include: v Working with Positive and Negative Integers v Fraction/Decimal Conversions v Order of Operations v Angles v Working with a Calculator v Temperature Conversions v Formulas 6

7 M501 Mechanical Troubleshooting Techniques This course is designed to teach the student techniques to become a better troubleshooter. They learn the correct use of instruments and devices to diagnose problem areas. Some of the topics covered include: v Bearings Basics v Lubrication Basics v Basics of Drive Systems v Components V-belts Chain drives Coupling types Electric motors Applications Proper installation v Preventative Maintenance Techniques v Root Cause Failure Analysis v Predictive Maintenance Techniques Ultrasonics Vibration Analysis Thermography 7

8 M502 Bearings Seminar Duration: 1 Day This course covers the various types of bearings and their applications. Reasons for bearing failure and how to apply the principles of preventive and predictive maintenance are discussed. The principles and techniques of bearing lubrication are also covered. Bearings #502 is a one-day course, but is usually coupled with Lubrication #503 and presented as a two-day seminar. Some of the topics include: v Bearing Construction v Application v Proper Maintenance v Precision Measuring of Bearing Housings and Fits (Hands-on) v Bearing Numbering Systems v Failure Analysis v Proper Maintenance Techniques M503 Lubrication Seminar Duration: 1 Day This course is intended to teach the student to distinguish between when it is appropriate to use grease and when it is appropriate to use oil when lubricating machinery. The different types of lubricants will be discussed. Several lubrication techniques will be covered. Some of the topics include: v Lubrication Types v Applications v Proper Schedules v Failure Analysis v Lubricant Oil Analysis v How the Lubrication Plan for a Machine can Increase its Reliability 8

9 M504 Maintenance of Mechanical Drives This course covers the different mechanical components that drive machinery. It includes gears, chain drives, v-belt drives, types of couplings, and their proper applications. Troubleshooting and preventive and predictive maintenance techniques are discussed. Sizing of drives and increasing reliability of drive components are covered in detail. Some of the key topics covered are: v Basics of Mechanical Drive Components - increasing life and adding reliability v Bearings - types, numbering, installation, and maintenance. v Couplings - types, purpose, and applications v Gear Drives - types, ratios v V-Belt Drives, types, sizing and alignment v Chain Drives - design, types, and maintenance v Proper Lubrication Techniques v The Importance of Proper Alignment - the Four Step Method of Precision Alignment is demonstrated. 9

10 M505 Precision Alignment Seminar Duration: 2 Days This course stresses the importance of shaft alignment. Students are taught how to use precise, accurate methods to achieve precision measurements and thereby increase equipment life. This course includes how to use dial indicators, micrometers, Vernier calipers, and other precision tools necessary to measure and compare fits and tolerances of machine components with the proper measurements necessary for effective, reliable repair. The 4-Step Rim and Face technique is practiced and perfected. The Reverse Dial and Laser methods are also explained and discussed. This is a hands-on course where the student actually aligns mock-up drives in the classroom. It is a lot of fun and the key to all successful mechanical repairs. This class is sure to add reliability and reduce mechanical breakdowns. According to an ITTT study, as many as 43% of all mechanical failures are the direct result of the misalignment of mechanical components. Some of the key topics covered are: v Precision Measurement Methods v Reading Micrometers v Reading Vernier Calipers v Dial indicators v Fits and Tolerances v Basic Math Refresher v Alignment - The Four Step Method (hands-on), Reverse Dial Method, and Laser 10

11 M506 Centrifugal Pumps Seminar Duration: 2 Days This course teaches the student the basic principles of centrifugal and positive displacement pumps. Theory is taught and then applied. Troubleshooting is taught by checking measurable parameters such as discharge pressure, suction pressure, and amperage. Performance of the pump is then matched to design limits and the Pump Curve becomes a valuable troubleshooting tool. Proper application and maintenance are stressed. Various sealing methods are covered, and several types of packing and mechanical seals are discussed. All topics are discussed in simple, easy to understand and apply language. Proper maintenance techniques and lubrication are covered in detail; along with basics of electric motors, bearings, seals, and alignment. Cavitation, Recirculation, Net Positive Suction Head and Vibration are discussed and defined. This course is bound to add reliability to your pumping systems. Some of the key topics covered are: v History of Pumping v Theory of Centrifugal and Positive Displacement Pumps v Proper Application of Pumps v Pump Curves v Troubleshooting Pumps and Systems v Pump Affinity Laws v Understanding NPSH (Net Positive Suction Head) v Proper Installation v Vibration Analysis as a Valuable Tool v Proper Maintenance Techniques v Basics of Proper Alignment v Cost of Pumping v Variable Frequency Drive Advantages, Energy Savings, and Applications 11

12 M507 Fans and Blowers Seminar Duration: 1 Day This course explains the basic operating principles of fans and blowers and how to apply them to troubleshooting and predictive maintenance techniques. Fans and Blowers #507 is usually combined with Air Compressors #509 for a 2-day session that would include the following: v Basic Theory v Fan Laws v Air Density and Temperature Relationships v Efficiency v Energy Requirements v Applications v Recommended Maintenance Practices. v Includes both preventative maintenance and predictive maintenance in the form of vibration analysis, balancing, and oil analysis. M508 Vibration Analysis Seminar Duration: 1 Day This course teaches the student the importance of identifying the source and/or cause of vibration in machinery. Devices and techniques for performing vibration analysis are covered. Topics include: v Vibration Analysis as an Effective Predictive Maintenance Tool v Devices v Techniques 12

13 M509 Air Compressors Seminar Duration: 1 Day This course covers the principles of air compressors. The different applications for air compressors are also discussed. Proper maintenance is stressed. Air Compressors #509 is usually combined with Fans and Blowers #507 for a 2-day session that would include the following: v Basic Theory v Fan Laws v Air Density and Temperature Relationships v Efficiency v Energy Requirements v Applications v Recommended Maintenance Practices. v Includes both preventative maintenance and predictive maintenance in the form of vibration analysis, balancing, and oil analysis. M510 Precision Measurement Seminar Duration: 1 Day This course stresses the importance of precise measurements in the industrial environment. Students are taught how to use a variety of instruments and devices used in precision measurement applications. Topics include: v History v Vernier Calipers v Micrometers v Dial Indicators 13

14 M511 Air Conditioning and Heating Basics Seminar Duration: 5 Days This is a five-day intensive course designed to teach the maintenance professional the basic thermodynamic principles of air conditioning and heating. It is also designed to familiarize the student with the operation and maintenance of various air conditioning and heating systems and system components. This course additionally teaches the student the safety and environmental aspects of working with refrigeration gasses. It includes training to prepare the student to take the EPA test for Refrigeration Technician certification, which is also offered as part of this course. Some of the key topics covered are: v Working with Refrigeration Systems - tools, practices, soldering, brazing principles v Basic Thermodynamic Principles v Temperature and Pressure v The Refrigeration Cycle v System Components v Refrigerants - blends v Refrigerants - recovery and recycling v Troubleshooting Refrigerant Problems v Compressors - flow controls, lubrication v Basic Electrical Controls v Basics of Gas Heat with Air Conditioning v Basics of Oil Heat with Air Conditioning v Basics of Electrical Heat with Air Conditioning v Heat Pumps 14

15 M512 Air Conditioning and Refrigeration This course covers the principles and applications of air conditioning and refrigeration. The methods of maintaining AC&R systems is also covered, as well as the environmental laws that control these methods. This course additionally teaches the student the safety and environmental aspects of working with refrigeration gasses. It includes training to prepare the student to take the EPA test for Refrigeration Technician certification, which is also offered as part of this course. Topics include: v Working with refrigeration systems, tools, practices, soldering, brazing principles v Basic thermodynamic principles v Temperature and pressure v The refrigeration cycle v System components v Refrigerants - blends v Refrigerants recovery and recycling v Troubleshooting refrigerant problems v Compressors, flow controls, lubrication v Basic electrical controls v Basics of gas heat with air conditioning v Basics of oil heat with air conditioning v Basics of electrical heat with air conditioning v Heat pumps 15

16 M513 EPA Exam Preparatory Course This course is designed to prepare the student for their Type I, Type II, and/or Type III certification in refrigerant purchase and handling. Upon completion of the course work, the student is offered the opportunity to sit for the EPA (Environmental Protection Agency) Exam administered by Industrial Trainers of America, Inc. Actual certification is granted by ESCO INSTITUTE. Topics include: v Types of Refrigerants v Applications v Refrigerant Recovery v Safety v Federal Clean Air Act M514 Boilers This course is designed to familiarize the student with the different types of steam boilers and systems. It covers the equipment and accessories, instruments, water treatment, operation and maintenance of boilers. Topics include: v Steam Boilers v Fittings and Accessories v Basic Boiler Room Systems v Fuel Burning Equipment v Draft v Combustion v Instruments v Boiler Water Treatment v Operation 16

17 M515 Welding This is a three-day course designed to familiarize maintenance personnel with different types of welding, their processes, and safety issues regarding welding. Some of the key topics covered are: v Introduction to Welding Oxyacetylene Processes Basics of metallurgy Welding and cutting processes The physics of welding Variations of weld joints and positions Welding safety v Shielded Metal Arc Welding SMAW welding equipment and supplies SMAW welding equipment adjustment and assembly Welding electrodes What process and technique to use and when Hands-on setup and practice exercises, and fabrication using several techniques v Oxyacetylene Processes Oxyacetylene setup and safety Equipment and supplies Assembly and adjustment Welding and cutting techniques Welding joints, and positions Brazing Oxyacetylene cutting Hands-on projects and fabrication exercises v Tungsten Arc Gas Welding-TIG,Heliarc TGAW welding safety TGAW welding theory TGAW welding equipment/materials TGAW uses and techniques Hands-on practice exercises and fabrication projects 17

18 M516 Basic Pneumatics This is a three-day course designed to familiarize maintenance personnel with pneumatics as they relate to industrial machinery. Students will learn how pneumatic components work and how to properly maintain pneumatic systems. Some of the key topics covered are: v Force Transmission Through a Fluid v Energy Transmission Using Pneumatics v Control of Pneumatic Energy v Compressor Types v Air Distribution Systems v Operation of Pneumatic Components - cylinders, etc. v Directional Control Valves v Flow Controls v Regulators v Various Hands-On Exercises to Demonstrate Principles M517 Basic Hydraulics This is a three-day course designed to familiarize maintenance personnel with hydraulics as it relates to industrial machinery. Students will work with fluid power principles and experience the functional characteristics of hydraulic components, which include pumps, flow control valves, pressure valves, directional control valves, cylinders, etc. Proper maintenance of hydraulic systems along with troubleshooting techniques will be discussed. Some of the key topics covered are: v Hydraulic Transmission of Force and Energy v Hydraulic Fluids v Operation of Hydraulic Pumps v Hydraulic Actuators cylinders, motors v Control of Hydraulic Pressure v Check Valves, Flow Control Valves v Directional Control Valves v Pilot Operated Control Valves v Reservoirs, Coolers, Filters v Various Hands-On Props and Exercises to Demonstrate Principles 18

19 M518 Pipefitting This course is designed to provide the maintenance mechanic with the information to safely complete the repair procedures on fuel gas, steam, condensate, stock, air, hydraulic, fire, city and mill water piping systems. Topics include: v History v Systems v Maintenance v Repair v Safety E600 Electrical Troubleshooting This is a three-day course is designed to familiarize the maintenance professional with basic electrical circuits, electrical safety in troubleshooting, electrical drawings and schematics, electrical distribution systems, wiring and troubleshooting of motor control circuits, electrical protective devices, and AC motors as they relate to electrical troubleshooting. Some of the key topics covered are: v Basic Electrical Circuits Ohm's Law Kirchoff's Law Series, parallel, and combination circuits Use of test equipment Hands-on circuit exercise v Electrical Safety in Troubleshooting Basics of electrical safe work practices Lock Out Tag Out Personal protective equipment and electrical troubleshooting v Electrical Drawings and Schematics Review of electrical print reading One-line diagrams Ladder Diagrams Electrical symbols v Electrical Distribution Systems Transmission relays Transformers Single-phase, three-phase power systems One-line diagrams v Wiring and Troubleshooting of Motor Control Circuits 19

20 Basic control components Wiring basic control circuits (hands-on) Sizing of thermal overload protection Troubleshooting of motor control circuits Hands-on wiring and troubleshooting "bugged" control circuits Two-wire control circuits Three-wire control circuits v Electrical Protective Devices Explanation of protective devices Fuses Circuit breakers Phase monitors Thermal motor overloads v AC Motors Single-phase Three-phase Troubleshooting and testing Proper preventive and predictive maintenance Torque characteristics Why motors fail Meggering, surge comparison testing 20

21 E601 Motor Controls and Troubleshooting Seminar Duration: 2 Days This is a two-day course designed to familiarize maintenance personnel with the different types of motor controls and their applications. Some of the key topics covered are: v Review of Basic Electrical Circuits v Ohm s Law v Kirchoff s Principles v National Electrical Code Requirements Relating to Motor Controls v Review of Wiring - one line and ladder diagrams v Electrical Safety Issues Dealing with Electrical Motor Control Circuits, Repair, and Troubleshooting v Motor Control Circuit Fundamentals v Hands-On Wiring and Troubleshooting Several Basic Motor Control Circuits v General Rule of Thumb Troubleshooting and Diagnostic Practices v Basics of Electrical Protective Devices 21

22 E602 Ladder Diagrams This course teaches the student how to read basic electrical ladder diagrams. The special symbols used in electricity are learned. E603 Grounding and Bonding This course covers the basic theory and principles of grounding and bonding of electrical systems and related equipment. Safety aspects are covered in great detail. E604 AC Motors This course teaches the student about alternating current motors and their applications. Proper maintenance of AC motors is also covered. E605 AC Motor Controls This course teaches the student about the different components that "start and stop" a motor. 22

23 E606 Industrial Electricity Basics This course covers the basic principles of electricity and how they apply to the industrial environment. Electrical safety is also stressed. This course includes the information on industrial electrical subjects necessary to troubleshoot, repair, and maintain most industrial electrical equipment. This course is not only for the novice, but serves as an excellent refresher for the experienced electrician. It is also well-suited for the non-electrician for the purpose of cross craft training. With the highly complicated interrelationships of electrical and mechanical systems in most modern equipment, this course eliminates the age-old argument of whether the problem is mechanical or electrical. Follow-up to this course is our AC Motor Controls course, which consists of two days of handson fun wiring and troubleshooting common motor control circuits. Some of the key topics covered are: v Basic Electrical Principles, Ohm s Law, Kirchoff's Law v Digital Multimeter hands-on circuit tests v Basics of Direct Current, Series, Parallel, and Combination Circuits v Basics of Alternating Current, The Induction Effect v Transformers v Industrial Power Distribution Systems v Electrical Protective Devices, Fuses, Circuit Breakers, Phase Monitors v Basics of AC Motors - Single and Three-Phase v Basics of Electrical Schematics and Blue Print Reading v Basics of Electrical Preventive and Predictive Maintenance v Electrical Safe Work Practices - based on OSHA Standard 29CFR

24 E607 OSHA Electrical Safety Training Seminar Duration: 2 Days Prerequisites: The attendee should have a basic knowledge of industrial machinery, math, and electrical principles. This course is designed to raise awareness of electrical hazards in the workplace, and to point out the "safe" way to work with electricity. It follows the requirements of OSHA CFR that covers scope, training, work practices, use of equipment, and safeguards for personnel protection. The Occupational Safety and Health Act is also explained, as well as electrical dangers of shock, arc, and blast. The Occupational Safety and Health Act includes the following: v Introduction (OSHA) Introduction Employer and employee responsibilities Inspections Penalties NFPA 70E committee v Electrical Hazards Shock Arc Blast v Working on electrical equipment Electrical switching Electrical testing Grounding Equipment, planning morale v Electrical safety-related work practices OSHA 29 CFR Part Scope Training Selection and Use of Work Practices Lockout and Tagout Use of Equipment Safeguards for Personnel Protection 24

25 E608 PLC Basics This course covers the basic principles and applications of programmable logic controllers. E609 Variable Frequency Drives This course teaches the student the fundamental principles and applications of variable frequency drives. E610 Electrical Systems/Transformers This course teaches the student about different types of electrical systems. It covers the different types of electrical transformers and their various applications. E611 Cross-Craft Industrial Electricity This course is designed to teach students other than electricians the basic principles of industrial electricity and motor controls. It also addresses the safety precautions that they should take when dealing with electricity. This course is intended to help workers in industry avoid the hazards that they may encounter while performing electrically related jobs. E612 NEC National Electrical Code This course is designed to give students an understanding of the National Electrical Code and its changes for

26 E613 Instrumentation Measurement and Control Basics This course is designed to teach students the fundamentals of pneumatic, electrical, electronic, and digital instrumentation. v Process Measurement Flow Pressure Level Temperature v Pneumatic Instrumentation Fundamentals v Electrical and Electronic Instrumentation Fundamentals v Digital Instrumentation Fundamentals v Primary Elements Orifice plate Venturi tube Pitot tube Magnetic flowmeter Ultrasonic flowmeter Capacitance detector Ultrasonic detector Bimetallic devices v Secondary Elements Transducers Diaphragm devices Bellows devices v Transmitters v Controller Modes Off/On Modulating control (PID) v Final Control Elements (control valves) v Instrumentation Drawings Loop P&ID v Introduction to Process Control Computer System 26

27 E614 NFPA 70E Arc Flash Seminar Duration: 1,2, or 3 Days This course is designed to teach students the current standards of NFPA 70E as it relates to the electrical safety hazard known as Arc Flash. The regulations that require the calculation of the flash protection boundary inside which qualified workers must be protected when working are discussed. 27