Industrial Mechanic (Millwright) Level 4
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1 Level 4 Rev. September 2005
2 Unit: A3 Pre-Interprovincial Review 50 hours Theory: Practical: 50 hours 0 hours This unit offers apprentices a systematic review of skills and knowledge required to pass the Interprovincial Red Seal Examination. It provides the connections between on-the-job learning and the content of in-school technical training. technical training. The unit includes pertinent information about the significance of Red Seal IP certification and the main features of the IP exam. Objectives and Content: No testing is prescribed for this instructional unit; a Pass grade will be awarded for participation in this unit. 1. Describe the significance, format, and general content of Interprovincial Red Seal Examinations. a. Scope and aims of Red Seal system; value of certification b. Obligations and entitlements of candidates for IP certification Relevance of IP Examination to current, accepted trade practices; industry-based national validation of test items Supplementals Policy (retesting) by the Apprenticeship Branch Confidentiality of examination content; the certified journeyperson s own stake in examination security (value of credential) Limitations on use of calculators (cannot be programmable) c. Multiple-choice (four-option) item format; Red Seal and Apprenticeship Branch standards for acceptable test items (e.g. no trick -type questions; specifications for use of metric/imperial units) d. Important government materials relevant to the IP Examination for apprentice industrial mechanics (millwrights) National Occupational Analysis (NOA); prescribed scope of the skills and knowledge which comprise the trade NOA Pie-chart and its relationship to content distribution of IP Examination items Manitoba Apprentice Portfolio, especially the NOA-based Practical Record Book and task and subtask checklists 2. Identify resources, strategies, and other key considerations for maximizing successful completion of written exams used in certifying tradespeople. a. Personal preparedness b. Proper rest and nutrition, eye-testing c. Making room for a personal study regimen d. Focused reflection on prior test taking e. Self-assessment and a Personal Study Plan Preliminary self-assessment of individual strengths and weaknesses in trade-related skills and knowledge; usefulness of old tests; usefulness of Apprenticeship Portfolio checklists and reflection on the in-school and on-the-job components of the Apprenticeship Program Use(s) of approved textbooks, chapter tests, study guides, and notetaking in preparing for an 1 Rev. September 2005
3 examination Study groups; perils and possibilities Formulation of a personal study plan, including an approximate timetable, which describes and schedules a course of action for reviewing all relevant material(s) and for strengthening areas of deficient skills and knowledge 3. Review program content a. Occupational skills Trade Safety Communication Pre IP review b. Shop practice Measurement and Measuring Devices Layout Non-cutting Hand Tools Cutting Hand Tools Fasteners Metallurgy Lubrication Practices c. Engineering Drawings Read and Interpret Drawings I Read and Interpret Drawings II d. Machine Components and Operations Drilling Machines Power Metal Saws Pedestal Grinders Metal Lathe Milling Machines e. Welding Welding I Welding II f. Rigging and Cranes Rigging Install Cranes, Troubleshoot and Maintain Rigging, Hoisting and Lifting Equipment g. Installation and Maintenance of Components and Systems Gaskets, Seals and Packing Bearings Couplings and Clutches Drives Prime Movers I Diesel 1 Prime Movers II Diesel 2 Prime Movers III Steam and Gas Turbine Installation and Erection of Machinery Conveyors h. Fluid Power Hydraulics I Hydraulics II Pneumatics I Pneumatics II Introduction to Electricity Electrical Control Programmable Logic Controllers (PLCs) i. Reliability Centered Maintenance Preventative and Predictive Maintenance Vibration Analysis Developing Troubleshooting Skills 2 Rev. September 2005
4 Unit: G6 Prime Movers II Diesel 2 40 hours Theory: 20 hours Practical: 20 hours This unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to understand the advanced operation of internal combustion engines, turbines and electric motors. Material covered includes: Internal combustion engines Percent of Objectives and Content: Unit Mark (%) 1. Describe advanced principles of operations 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. Troubleshoot, disassemble, reassemble and inspect advanced engine performance problems. 50% a. Routine maintenance practices b. Shut down 3. Describe the advanced principles of operation for diesel engines. 25% 3 Rev. September 2005
5 Unit: G7 Prime Movers III Steam and Gas Turbines 20 hours Theory: 20 hours Practical: 0 hours This unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to understand the operation of turbines and electric motors and in compliance with safety procedures. Material covered includes: Compliance with safety procedures Steam and gas turbines Percent of Objectives and Content: Unit Mark (%) 1. Describe the principles of operation of steam turbine drives. 25% 2. Describe the components and accessories used on steam turbines. 25% a. Impulse and reaction blades b. Shaft attachments c. Shrouds d. Journal bearings e. Thrust bearings f. Steam chests and nozzle blocks g. Diaphragms and steam nozzles h. Disc and drum rotor diaphragms i. Shaft seal purpose j. Carbon seals k. Labyrinth seals l. Shaft steam seal system m. Turbine condenser and hot well n. Main stop valves o. Exhaust valves p. Throttle valves q. Overspeed trips r. Governors valves s. Extraction valves t. Governor types and operation u. Lubricating systems v. Turning gears w. Jacking pumps 3. Describe the principles of operation for gas turbines. 25% a. Difference between gas and steam turbines b. Types of gas turbines c. Classifying gas turbines by cycle: 4 Rev. September 2005
6 Simple open cycle Complex cycle d. Classifying gas turbines by shaft arrangement: Single shaft turbines Two shaft turbines 4. Describe gas turbine components and their purpose. 25% a. Compressor types b. Combustion: Igniter Fuel atomizer Flame tube c. Turbines Blade cooling Blade shapes and roots Bearings and shaft seals d. Governors e. Lubrication systems 5 Rev. September 2005
7 Unit: H2 Hydraulics II 45 hours Theory: 30 hours Practical: 15 hours 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 skills necessary to install and maintain pipes and piping assembly related to Industrial Mechanic (Millwright). Material covered includes: Troubleshooting Testing equipment Percent of Objectives and Content: Unit Mark (%) 1. Describe the components and accessories used on steam turbines. 2. Identify safety precautions when working with positive displacement pumps. 15% 3. Troubleshoot and repair common positive displacement pumps:. 15% a. Leakage b. Pressure and flow loss c. Noisy pump operation d. Describe start up and shut down procedures Checking for rotation Priming Checking for proper operating temperature Draining before maintenance 4. Use schematics to determine the series of operation and locate problems in a system. 10% a. Understanding symbols b. Trace fluid flow in a hydraulic circuit 5. Describe preventive maintenance procedures. 45% a. Cleaning strainers b. Changing filters c. Changing hydraulic fluids 6. Use testing equipment to determine system faults. 15% a. Troubleshooting practices b. Pressure gauges and flow meters 6 Rev. September 2005
8 Unit: H4 Pneumatics II 12 hours Theory: 6 hours Practical: 6 hours This unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to troubleshoot and repair various components of a pneumatic system using testing equipment and schematics. In addition, this unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to troubleshoot vacuum components and systems. Percent of Objectives and Content: Unit Mark (%) 1. Describe procedures to troubleshoot and repair various components of a pneumatic system using testing equipment and schematics. 100% 7 Rev. September 2005
9 Unit: I1 Preventive and Predictive Maintenance 30 hours Theory: 15 hours Practical: 15 hours This unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to understand the importance of preventive and predictive maintenance and in compliance with safety procedures. Material covered includes: Compliance with safety procedures Maintenance styles Record keeping Percent of Objectives and Content: Unit Mark (%) 1. Describe various maintenance styles. 25% a. Breakdown maintenance b. Preventive maintenance c. Predictive maintenance d. Proactive maintenance e. Total productive maintenance f. Preventive engineering g. Reliability engineering h. Productive maintenance 2. Describe the basic components of a preventive maintenance program. 25% a. Equipment record files b. Equipment repair history c. Inspection reports d. Priority system 3. Describe basic procedures followed under preventative maintenance programs. 25% a. Vibration analysis b. Lubrication c. Bearing failure analysis d. Performance monitoring e. Key frequency and RPM f. Dynamic Balancing g. Non-destructive testing: Types Visual inspection Dye penetrant inspection Magnetic particle inspection and eddy current inspection Ultrasonic inspection Radiographic inspection 8 Rev. September 2005
10 4. Describe the purpose of oil analysis. 25% a. Particle analysis b. Gravimetric level analysis c. Spectrographic oil analysis d. Ferromagnetic analysis e. Total base number tests f. Total acid number tests g. Infrared tests h. Water content tests 9 Rev. September 2005
11 Unit: I2 Vibration Analysis 36 hours Theory: 26 hours Practical: 10 hours This unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to collect data, detect and diagnose vibration levels. In addition, this unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to collect, plot and to execute calculation of data to correct different types of unbalance. Material covered includes: Compliance with safety procedures Data collectors PC software Vibration terminology Causes of unbalances Balancing terminology Computers and related software Percent of Objectives and Content: Unit Mark (%) 1. Identify and explain causes of vibration. 20% a. Causes of vibration: Imbalance Mechanical looseness Aerodynamic flow imbalances V belt drives Gear drives Bearings Machine overload Misalignment Bent shafts Electrical imbalances Hydraulic fluid imbalances 2. Identify and define vibration terminology. 20% a. Vibration Terminology Definition of vibration Frequency Displacement Velocity Acceleration Ultrasonic Noise 10 Rev. September 2005
12 3. Describe and explain purposes of vibration analysis methods. 15% a. Analysis Diagnostic methods Analyzing methods Interpreting information 4. Describe and discuss vibration problems with a view of arriving at solutions to those problems. 15% a. Vibration problem solutions Equipment manufacturer specifications Equipment modifications Modifying equipment operation procedures 5. Describe and discuss types of balancing. 10% a. Types of balancing Static Dynamic Harmonic 6. Identify balancing methods. 10% a. Methods of balancing Static balancing Dynamic balancing single plane and two plane balancing Strobe lights position of imbalance, correct weights, and weight position 7. Identify purpose of balancing. 10% 11 Rev. September 2005
13 Unit: I3 Developing Troubleshooting Skills 47 hours Theory: 32 hours Practical: 15 hours This unit of instruction is designed to provide the Industrial Mechanic (Millwright) apprentice with the knowledge and skills necessary to troubleshoot. Percent of Objectives and Content: Unit Mark (%) 1. Identify and describe troubleshooting. 10% a. Efficient troubleshooting in a production plant b. common troubleshooting aids c. Steps in troubleshooting a system d. Typical maintenance organization 2. Describe concepts of working with other people. 10% e. Good communication between plant personnel f. Ways a person usually sees himself/herself g. Communication cycle h. Correct method of delivering a written message from your supervisor to another person 3. Describe troubleshooting techniques. 10% a. Steps to recognize normal machine operations b. Questions to consider when a machine fails c. Signs of a machine in need of service 4. Identify aids to troubleshooting. 10% a. Blueprints b. Information that should be recorded in a machine equipment record c. Calibration standards d. Multimeter (VOM) e. Different troubleshooting test equipment 5. Identify process of preparation for troubleshooting. 10% a. Mechanical or electrical systems information that is essential prior to successfully troubleshooting b. a mechanical or electrical system c. Commonly used items that should be carried in a troubleshooter s toolbox d. Steps to follow in reading a pneumatic or hydraulic schematic e. Responsibilities of a troubleshooter 6. Identify use of schematics and diagrams. 10% a. How to use schematics when troubleshooting 12 Rev. September 2005
14 b. Identification of differences in schematics c. Procedure to use a troubleshooting chart 7. Identify how to solve mechanical problems. 10% a. Bearing wear problems b. Pump failure problems and solutions c. Types of housing d. Different plant equipment and their problems 8. Identify how to solve electrical problems. 10% a. Definition of switchgear b. Current voltage characteristics of wire c. Safety rules to follow when working with electrical equipment d. Identification of a pictorial diagram, a block diagram and a schematic diagram e. Procedure to troubleshoot an electric problem 9. Identify breakdown maintenance. 10% a. Responsibilities of first member of the emergency crew b. Spare parts requisition form c. main parts of practical machine maintenance 10. Identify planned maintenance. 10% a. Definition of planned maintenance b. Machine inventory information c. Benefits to be accrued from an effective lubrication program d. Proper sag in a drive chain e. Procedure to service a battery 13 Rev. September 2005
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