INDUSTRIAL MECHANICAL MAINTENANCE

PROGRAMME OUTLINE

 DURATION: 9 Months

Section 1 Core Modules

• HEALTH, SAFETY AND ENVIRONMENT

• Attire, Cleanliness and Attitude •Analysis of Hazardous Situations •Identification and elimination of hazards

•Care and proper use of PPE •Company Health and Safety Policies and Procedures

•Equipment safety interlock, permissive and guards •General safety rules for Workshop and Industry

•Apply First Aid and CPR in the Workplace •Operate Fire Prevention equipment

•PROPER USE AND CARE OF HAND AND POWER TOOLS

•House Keeping/Identification of Tools•  Power and Hand Tools Safety

•Selection and Proper Use of Tools (hand and power) •Inspection, Care and Maintenance of Tools (Hand and Power)

•MEASUREMENT – DIRECT AND INDIRECT/PRECISION

•Identify the various measuring devices •Care and Maintenance of measuring devices

•Use measuring devices to take measurement •State the difference between direct and indirect measurement

•Calibrate and reset faulty measuring device•  Safety

- WORKSHOP PRACTICALS

•WORK PLANNING AND PROCEDURES

•Will be able to prepare planned Maintenance Schedule

•Use a step-by-step approach for disassembly/assembly of equipment. •Prepare a critical analysis or equipment

•Prepare spare parts list •Prepare equipment daily check list

•WORKSHOP PRACTICALS

•CUTTING AND FITTING OF GASKETS

•Identify and select various types of gaskets material •Layout gasket and cutting gasket •Installation of gaskets

•Types of gaskets •Purpose and uses of gaskets

•WORKSHOP PRACTICALS

•Simple Rigging •Selection of correct size of rigging equipment •Proper rope sling care and handling

•Rigging using hitches and knots and ties •Selection and care of rigging equipment •Safe rigging practices

•WORKSHOP PRACTICALS

•VALVES

•Types of valves •Design and construction of valves •Selection of valves •Maintenance and repair of valves

•Disassembly, inspection and reassembly of valves •Valve safety •Uses and operations of valves

•WORKSHOP PRACTICALS

•SEALING DEVICES/PACKING

•Packing material and type •Selection of packing •Installation of packing (pump/valve)

•Use of correct tools for removal and installation of packing

•WORKSHOP PRACTICALS

•SEALING DEVICES – MECHANICAL SEALS

•Types of seals •Selection of seals •Removal, installation and operation of mechanical seals

•Identification of seal failures •Care and handling of mechanical seals

•WORKSHOP PRACTICALS

•INTRODUCTION TO BEARINGS

•Introduction to bearings •Types of bearings •Design and Construction of bearings

•Bearing material and selection •Use of bearing catalog •Identify problems associated with bearings

•Safety on Handling bearings •Storage of bearings

•WORKSHOP PRACTICAL

•BEARING INSTALLATION AND REMOVAL

•Bearing fits and clearances •Removal and Installation of bearings

•Tools associated with removal and installation of bearings. •Cutting, lubrication grooves on plain bearings

•Selection and installation of lubrication devices on bearings

•WORKSHOP PRACTICALS

•LUBRICATION

•Introduction to lubrication •Types of lubricants •Properties of lubricants •Lubrication devices

•Viscosity •Lubrication of equipment

•WORKSHOP PRACTICAL

 •GEARS AND GEAR REDUCERS

 •Types of gears and reducers •Installation and adjustment of gear and reducers

•Maintenance and troubleshooting gears and reducers •Cleaning and lubrication of gears and reducers

•Uses of gears and reducers

•WORKSHOP PRACTICALS

 •COUPLINGS AND COUPLING INSTALLATION

•Types of couplings •Design and construction of couplings •Selection of couplings

•Installation and removal of couplings •Fits and clearances of couplings

•Tools used for removal and installation of couplings •Maintenance and coupling failure

•WORKSHOP PRACTICALS

•BELT AND CHAIN DRIVES

•Types of belts and chain drives •Construction of belts and chains

•Design and construction of pulleys and sprockets •Installation of belts and chains

•Maintenance of belt and chain drives •Tensioning and alignment of belt and chain drives

•Cleaning, Inspection and troubleshooting belt and chain drives

•WORKSHOP PRACTICALS

•BRAKES AND CLUTCHES

•Types of brakes and clutches •Installation and maintenance of brakes and clutches

•Adjustments of brakes and clutches •Uses of brakes and clutches

•WORKSHOP PRACTICALS

•PUMPS

•Types of pumps •Design and construction of pumps •Selection of pumps •Pump terminology and operation

Pump maintenance•  Pump disassembly, inspection and reassembly•  Pump failures and troubleshooting

•WORKSHOP PRACTICALS

•COMPRESSORS

•Types of compressors •Design and construction of the compressor •Selection of compressor

• Installation and operation of the compressor •Compressor Auxillances •Troubleshooting compressors

•WORKSHOP PRACTICALS

•TURBINES

•Types of turbines •Design and construction of turbines •Installation and operation of turbines

•Maintenance and troubleshooting turbines •Uses of turbines

•WORKSHOP PRACTICALS

•FANS AND BLOWERS

•Types of fans and blowers •Installation of fans and blowers •Maintenance of fans and blowers •Uses of fans and blowers

•WORKSHOP PRACTICALS

•BOILERS

•Introduction to boilers •Types of boilers •Design and construction of boilers •Selection of boilers

•Operation and maintenance of boilers •Troubleshooting boilers

•WORKSHOP PRACTICALS

•INTERPRET FLOOR PLANS, WIRING DIAGRAMS, CIRCUIT DIAGRAMS FOR ESTIMATING AND WIRING INSTALLATIONS

•Interpret the different types of electrical diagrams and their respective symbols

•Use electrical drawings to compile a detailed material list for an assigned installation

•Wire installation using the drawings and the respective material listing.

•WORKSHOP PRACTICALS

•HEAT EXCHANGERS

•Types of heat exchangers •Design and construction of heat exchangers •Maintenance and cleaning of heat exchanger

•WORKSHOP PRACTICALS

•COOLING TOWERS

•Types of cooling towers •Design and construction •Maintenance of cooling towers

•WORKSHOP PRACTICALS

 •ALIGNMENT

 •Introduction to alignment •Types of alignment •Equipment required to be aligned •Eight (8) steps of alignment

•Measuring and correcting alignment •Alignment fixtures and jigs •Alignment tools

•WORKSHOP PRACTICALS

 •HYDRAULICS AND PNEUMATICS

•Introduction to hydraulics •Hydraulic principles and calculation •Design and construction of hydraulic system

•Hydraulic components •Operation of a typical hydraulic system •Troubleshooting hydraulic systems

•  Introduction to pneumatics•  Pneumatics components•  Design and construction or pneumatic system

•Troubleshooting pneumatic system

•WORKSHOP PRACTICALS

•APPLIED MATHS AND SCIENCE

•Introduction to SI Units •Addition subtraction, multiplication and division of whole numbers and fractions

•Calculations of lengths, perimeters, circumferences areas and volumes of various shapes

•Transposition of equations calculations with powers •Pythagoras theory

•Use of trigonometric formulas to solve problems •Calculation of simple and multiple belt drives

•Calculation of simple and multiple gear drives •Calculation of work, power efficiency and torque

•Calculation of forces and effects of forces on a body •Calculation of pressure and fluid calculation

•Calculation of mass, density and weight force •Calculation of speeds (rotational)

•FASTENERS

•Types of fasteners •Use of fasteners •Design of fasteners

•WORKSHOP PRACTICALS

•CONVEYORS

• Introduction to conveyors •Design and Construction of conveyors •Uses of conveyors

•WORKSHOP PRACTICAL

•TECHNICAL DRAWING

•Construction of lines •Dimensioning •Prepare free hand sketching •Isometric drawings •First angle projection

•Sectional drawings •Read and interpret drawings •Blue Print Reading ,

•Development of Cones, Pyramids, Pipe Intersections etc.

•MATERIALS TECHNOLOGY

•Types of metals and non metals •Properties of metals •Heat treatment of iron and steel •Production of iron and steel

•FABRICATION AND SHEET METAL WORK

•Layout tools and procedures •Use of layout tools to produce a job •Use to sheet metal tools to produce a job

•Safety when handling sheet metal

•WORKSHOP PRACTICALS

Section 2 SUPPLEMENTAL MODULES

4 Weeks BENCHFITTING

•Tools – cutting and non-cutting •Layout of work pieces •Use and Care of Tools•  Measurements

•WORKSHOP PRACTICALS

2 Weeks: BASIC ELECTRICITY

•Principles of Electricity •Use of the multi tester to test voltage, current, windings rotors etc.

•Mare a proper connection on a motor, starter, plug, light switch etc.•Proper use of cable tray to secure cable

•Maintain and trouble shoot electrical systems •Design and construction of electrical system •Electrical safety

•WORKSHOP PRACTICAL

2 Weeks: WELDING - GAS AND ARC

•  Welding Safety •Theory of gas welding •Theory of Arc Welding

•Connecting and preparing oxy fuel apparatus for Gas Welding •Regulating of Oxy fuel for Gas Welding

•Setting current for different types and size of electrodes •Preparation of work piece for Oxy Fuel and Arc Welding

•WORKSHOP PRACTICALS

1 Week: OSHA – Construction Safety (30 hrs)

1 Week: COMPUTER FUNDAMENTALS

•Basic Computer Outline •Microsoft Word •Microsoft Excel (5 days)

1 Week: LIFE LONG LEARNING

- Course Outline

•  PUMPS

•Types of pumps •Design and construction of pumps •Selection of pumps •Pump terminology and operation

•Pump maintenance •Pump disassembly, inspection and reassembly •Pump failures and troubleshooting

•WORKSHOP PRACTICALS

•COMPRESSORS •Types of compressors •Design and construction of the compressor •Selection of compressor

•Installation and operation of the compressor •Compressor Auxillances •Troubleshooting compressors

•WORKSHOP PRACTICALS

•TURBINES •Types of turbines •Design and construction of turbines •Installation and operation of turbines

•Maintenance and troubleshooting turbines •Uses of turbines

•WORKSHOP PRACTICALS

•FANS AND BLOWERS

•Types of fans and blowers •Installation of fans and blowers •Maintenance of fans and blowers •Uses of fans and blowers

•WORKSHOP PRACTICALS

•BOILERS •Introduction to boilers •Types of boilers •Design and construction of boilers •Selection of boilers

•Operation and maintenance of boilers •Troubleshooting boilers

•WORKSHOP PRACTICALS

•INTERPRET FLOOR PLANS, WIRING DIAGRAMS, CIRCUIT DIAGRAMS FOR ESTIMATING AND WIRING INSTALLATIONS

•Interpret the different types of electrical diagrams and their respective symbols

•Use electrical drawings to compile a detailed material list for an assigned installation

•Wire installation using the drawings and the respective material listing.

•WORKSHOP PRACTICALS

•HEAT EXCHANGERS

•Types of heat exchangers •Design and construction of heat exchangers •Maintenance and cleaning of heat exchanger

•WORKSHOP PRACTICALS

•COOLING TOWERS

•Types of cooling towers •Design and construction •Maintenance of cooling towers

•WORKSHOP PRACTICALS

 •ALIGNMENT

 •Introduction to alignment •Types of alignment •Equipment required to be aligned •Eight (8) steps of alignment

•Measuring and correcting alignment •Alignment fixtures and jigs •Alignment tools

•WORKSHOP PRACTICALS

 •HYDRAULICS AND PNEUMATICS

•Introduction to hydraulics •Hydraulic principles and calculation •Design and construction of hydraulic system

•Hydraulic components •Operation of a typical hydraulic system

•Troubleshooting hydraulic systems •Introduction to pneumatics •Pneumatics components

•Design and construction or pneumatic system •Troubleshooting pneumatic system

•WORKSHOP PRACTICALS

•APPLIED MATHS AND SCIENCE

•Introduction to SI Units •Addition subtraction, multiplication and division of whole numbers and fractions

•Calculations of lengths, perimeters, circumferences areas and volumes of various shapes

•Transposition of equations calculations with powers •Pythagoras theory

•Use of trigonometric formulas to solve problems •Calculation of simple and multiple belt drives

•Calculation of simple and multiple gear drives•  Calculation of work, power efficiency and torque

•Calculation of forces and effects of forces on a body •Calculation of pressure and fluid calculation

•Calculation of mass, density and weight force •Calculation of speeds (rotational)

•FASTENERS

•Types of fasteners •Use of fasteners •Design of fasteners

•WORKSHOP PRACTICALS

•CONVEYORS

•Introduction to conveyors •Design and Construction of conveyors •Uses of conveyors

•WORKSHOP PRACTICAL

•TECHNICAL DRAWING

•Construction of lines •Dimensioning •Prepare free hand sketching •Isometric drawings •First angle projection

•Sectional drawings •Read and interpret drawings •Blue Print Reading •Development of Cones, Pyramids, Pipe Intersections etc.

•MATERIALS TECHNOLOGY

•Types of metals and non metals •Properties of metals •Heat treatment of iron and steel •Production of iron and steel

•FABRICATION AND SHEET METAL WORK

•Layout tools and procedures •Use of layout tools to produce a job •Use to sheet metal tools to produce a job

•Safety when handling sheet metal

•WORKSHOP PRACTICALS

Section 2 SUPPLEMENTAL MODULES

4 Weeks BENCHFITTING

•Tools – cutting and non-cutting •Layout of work pieces •Use and Care of Tools •Measurements

•  WORKSHOP PRACTICALS

2 Weeks: BASIC ELECTRICITY

•Principles of Electricity •Use of the multi tester to test voltage, current, windings rotors etc.

•Mare a proper connection on a motor, starter, plug, light switch etc. •Proper use of cable tray to secure cable

•Maintain and trouble shoot electrical systems •Design and construction of electrical system •Electrical safety

•WORKSHOP PRACTICAL

2 Weeks: WELDING - GAS AND ARC

•Welding Safety •Theory of gas welding •Theory of Arc Welding

•Connecting and preparing oxy fuel apparatus for Gas Welding •Regulating of Oxy fuel for Gas Welding

•Setting current for different types and size of electrodes •Preparation of work piece for Oxy Fuel and Arc Welding

•WORKSHOP PRACTICALS

1 Week: OSHA – Construction Safety (30 hrs)

1 Week: COMPUTER FUNDAMENTALS

•Basic Computer Outline •Microsoft Word •Microsoft Excel (5 days)

1 Week: LIFE LONG LEARNING

- Course Outline