INDUSTRIAL EQUIPMENT MAINTENANCE

ONE YEAR PROGRAM

(600 CLOCK HOURS)

     The Industrial Equipment maintenance program is designed to provide training for present and future industrial maintenance personnel.

      Through classroom study, lectures, and hands on performance tasks, you will learn the skills necessary to become an Industrial Maintenance Mechanic.

 The following is a summary of the program units of study, or Content Standards and Objectives (CSO’S).

Fundamentals of Industrial Equipment Maintenance WVEIS Code 1873 XE "1873"

This course will introduce students to entry level skills in industrial maintenance occupations.  Students will become familiar with hand tools and power machines used in industrial mechanics and will perform a variety of operations using them.

Standard 1:  Identify, explore, and evaluate career opportunities related to industrial mechanics.(1873.S.1)

Career Opportunities Objectives

Students will:

1873.1.1    Describe a variety of careers related to industrial mechanics, and the training necessary to be successful in those careers.

1873.1.2    Develop appropriate attitudes and behaviors required to succeed in careers in the field of industrial mechanics.

1873.1.3    Identify sources of information about careers in industrial mechanics.

Standard 2:  Demonstrate knowledge of basic safety rules and equipment as it relates to industrial mechanics.  (1873.S.2)

Safety Rules Objectives

Students will:

1873.2.1    Recognize and follow general shop safety guidelines.

1873.2.2    Identify, select and demonstrate proper use and care of all basic personal safety equipment.

1873.2.3    Demonstrate the proper selection and use of fire extinguishers.

1873.2.4    Describe OSHA regulations necessary when using hazardous materials.

1873.2.5    Describe proper waste disposal of industrial lubricants.

Standard 3:  Select and apply industrial lubricants.  (1873.S.3)

Industrial Lubricants Objectives

Students will:

1873.3.1    Differentiate between oil, grease, and synthetic lubricants and describe various applications for each type.

1873.3.2    Explain how lubricants get contaminated.

1873.3.3    List possible handling and storage problems of lubricants.

Standard 4:  Straighten a shaft using a press.  (1873.S.4)

Shaft Objectives

Students will:

1873.4.1    Demonstrate the setup of an arbor press, shaft and dial indicator, take readings (data), explain run out, spring back, high point and flat spotting.

1873.4.2    Explain the effects of using heat on a shaft if used for straightening purposes.

1873.4.3    Differentiate between a normal shaft and a hardened shaft.

1873.4.4    Explain the magna fluxing and sonar devices for testing and inspecting for hairline cracks in shafts.

Standard 5:  Adjust gibs for full operation.  (1873.S.5)

Gibs Objectives

Students will:

1873.5.1          Describe the function of a gib and give examples of its application.

1873.5.2          Describe  “excessive wear” and “galled” in relationship to gibs.

1873.5.3          Explain the setup and reading of a dial indicator and micrometer for checking a gib.

Standard 6:  Fabricate and install safety guards.  (1873.S.6)

Safety Guards Objectives

Students will:

1873.6.1    Identify materials to be used, and illustrate safety guards to be fabricated and installed.

1873.6.2    Explain how a conveyor system functions and what guards are required.

Standard 7:  Assemble and align a drive mechanism for a conveyor system.  (1873.S.7)

Conveyor System Objectives

Students will:

1873.7.1    Identify different types of conveyor systems, where and why they are used.

1873.7.2    Explain alignment alternatives and various shimming techniques.

1873.7.3    Locate and explain manufacturer’s specifications of alignment data, capacity limitations, and assembly procedures.

Standard 8:  Identify basic tools used in industrial mechanics and perform various processes.(1873.S.8)

Basic Tools Objectives

Students will:

1873.8.1    Choose the proper tools for given applications, and describe the proper care and maintenance of each.

1873.8.2    Demonstrate adjustments necessary for each tool.

1873.8.3    Drill and tap internal threads and cut external threads of various size and pitch, using the proper thread cutting lubricants.

1873.8.4    Demonstrate the proper use of a band saw and power hack saw, and calculate the desired teeth per inch and cutting speed for various materials.

1873.8.5    Differentiate between tempering and annealing for ferrous and non-ferrous metals.

1873.8.6    Remove damaged screws or bolts, using various sizes and styles of screw extractors.

1873.8.7    Grind surfaces using portable electric grinder, using the proper abrasive.

1873.8.8    Demonstrate the use and maintenance of hand, pedestal and machine grinders by sharpening and deburring tools.

1873.8.9    Differentiate between drilling, boring, counter boring, spot facing, reaming and honing using a drill press, and demonstrate each procedure, using the proper lubricant.

1873.8.10   Mount work in universal lathe chuck, face work piece and center drill work piece.

1873.8.11   Bore and counter bore a hole and cut internal and external threads using lathe.

1873.8.12   Cut a horizontal surface and an external taper on lathe using compound rest.

Standard 9:  Inspect and troubleshoot moving parts on machines.  (1873.S.9)

Machines Objectives

Students will:

1873.9.1    Differentiate between damaged and normal set up using manufacturer’s specifications.

1873.9.2    Identify parts of gear box, open gear drive and explain gear alignments and meshing requirements.

Electrical Maintenance                                                WVEIS Code 1871 XE "1871"

This course will introduce students to the maintenance of electrical systems and motors in industrial maintenance occupations.  Students will become familiar with tools and components of electrical motors and will perform a variety of operations using them.

Standard 1:  Read and interpret electrical schematics and diagrams.  (1871.S.1)

Electrical Schematics and Diagrams Objective

Students will:

1871.1.1    Explain the difference between power and control circuits. 

Standard 2:  Replace electric motors and protective devices.  (1871.S.2)

Electric Motors and Protective Devices Objectives

Students will:

1871.2.1    Explain relevant sections of the National Electric Code.

1871.2.2    Calculate circuit amperage.

1871.2.3    Explain the difference between starting and running amperage.

1871.2.4    Explain and demonstrate how a magnetic contactor works. 

Standard 3:  Change rotation of electric motors.  (1871.S.3)

Electric Motors Objectives

Students will:

1871.3.1    Identify parts of a three-phase motor.

1871.3.2    Describe current flow in a three-phase motor. 

1871.3.3    Rewire a three-phase motor to change motor rotation.

1871.3.4    Describe current flow in a DC motor. 

1871.3.5    Rewire a DC motor to change motor rotation.

Standard 4:  Perform maintenance on electric motors.  (1871.S.4)

Maintenance Objectives

Students will:

1871.4.1    Explain lock out tag out rules.

1871.4.2    Explain types of motor controllers.

1871.4.3    Explain how to clean and lubricate motors.

Standard 5:  Use electrical test equipment to troubleshoot motor control circuits.  (1871.S.5)

Electrical Test Equipment Objectives

Students will:

1871.5.1    Obtain various readings with a VOM. 

1871.5.2    Test and replace semiconductors.

1871.5.3    Test DC power supplies. 

1871.5.4    Use transistors, diodes, and resistors in electrical circuits.

1871.5.5    Install and test silicon controlled rectifiers.

Hydraulics and Pneumatic Systems                        WVEIS Code 1875 XE "1875"

This course will introduce students to the application of hydraulic and pneumatic systems used in industrial maintenance occupations.  Students will become familiar with tools and components of hydraulics and pneumatics and will perform a variety of operations using them.

Standard 1:  Read and interpret hydraulic and pneumatic diagrams.  (1875.S.1)

Hydraulic and Pneumatic Diagrams Objectives

Students will:

1875.1.1    Identify and describe the function of component parts of hydraulic and pneumatic systems.

1875.1.2    Interpret symbols for hydraulics and pneumatics using CAD.

1875.1.3    Identify and describe mechanical servo valves and cartridge valves. 

Standard 2:  Refill or clean filters and refill system in hydraulic and pneumatic systems.  (1875.S.2)

Clean Filters and Refill System Objectives

Students will:

1875.2.1    Describe techniques for draining systems.

1875.2.2    Identify various filters, screen, strainers, and types of hydraulic and compressor oils. 

 

Standard 3:  Replace and align hydraulic motors and pumps.  (1875.S.3)

Hydraulic Motors and Pumps Objectives

Students will:

1875.3.1    Describe hydraulic pumps, the basic parts and the function of each part. 

1875.3.2    Explain how a hydraulic unit functions. 

1875.3.3    Identify alignment and couplings. 

1875.3.4    Align piston rod of hydraulic pump and adjust pressure.

Standard 4:  Install hydraulic and pneumatic lines and measure pressure.  (1875.S.4)

Install Hydraulic and Pneumatic Lines Objectives

Students will:

1875.4.1    Identify piping, fittings, gaskets, and seals. 

1875.4.2    Inspect and replace pressure relief valve.

Standard 5:  Install guards and covers.  (1875.S.5)

Guards and Covers Objective

Students will:

1875.5.1    Explain and use manufacturer’s specifications for clearance and attachment techniques.

Industrial and Commercial Wiring                            WVEIS Code 1765 XE "1765"

This course will introduce students to the special installation and characteristics of industrial and commercial wiring according to the National Electrical Code.

Standard 1:  Install conduit and raceways.  (1765.S.1)

Conduit and Raceways Objectives

Students will:

1765.1.1    List various types of conduit and their uses.

1765.1.2    List NEC code requirements for installation and construction of various conduit and raceway systems.

Standard 2:  Maintain lighting and receptacle outlets.  (1765.S.2)

Lighting and Receptacle Outlets Objectives

Students will:

1765.2.1    Explain and install emergency lighting systems.

1765.2.2    Diagnose and repair various lighting, receptacle and outlet problems.

Standard 3:  Demonstrate knowledge of industrial grounding methods.  (1765.S.3)

Industrial Grounding Method Objective

Students will:

1765.3.1    Explain grounding of single-phase and three-phase systems. 

Standard 4:  Demonstrate knowledge and skills associated with transformers.  (1765.S.4)

Transformers Objectives

Students will:

1765.4.1    List safety procedures used when working with transformers.

1765.4.2    Describe construction and operating characteristics of transformers.

1765.4.3    Illustrate various types of transformer connections and discuss the results of these connections.

1765.4.4    Connect dual-voltage transformers for high and low voltage operation. 

 

Rotating Devices and Control Circuitry                   WVEIS Code 1771 XE "1771"

This course will introduce students to basic control circuits, pilot devices, motor controls, relays, motor braking circuits, alternators and generators and how to troubleshoot AC and DC motors.

Standard 1:  Demonstrate safe work habits.  (1771.S.1)

Safe Work Habits Objectives

Students will:

1771.1.1    List and explain personal and electrical safety rules applicable to rotating equipment.

1771.1.2    List and explain hand and tool safety rules applicable to rotating equipment.

Standard 2:  Interpret blueprints, schematics, and block diagrams for control circuitry.  (1771.S.2)

Control Circuitry Objectives

Students will:

1771.2.1    Draw a block diagram of a motor control system.

1771.2.2    Demonstrate knowledge of elementary wiring diagrams and ladder logic.

1771.2.3    Install motor control centers and systems, using wiring diagrams.

1771.2.4    List and identify motor and motor control symbols.

Standard 3:  Demonstrate knowledge and skills applicable to pilot devices.  (1771.S.3)

Pilot Devices Objectives

Students will:

1771.3.1    Explain purpose and uses of pilot devices.

1771.3.2    Explain and list various types of electronic and mechanical sensors and pilot devices.

1771.3.3    Explain counter circuits.

1771.3.4    Install and troubleshoot various pilot devices and their circuits.

Standard 4:  Demonstrate knowledge and skills related to motor controls.  (1771.S.4)

Motor Controls Objectives

Students will:

1771.4.1    Explain the difference between manual and automatic circuits.

1771.4.2    List the equipment and parts needed for automatic circuits.

1771.4.3    Identify basic motor control circuits.

1771.4.4    Connect basic AC and DC circuits for automatic and manual control.

1771.4.5    Explain and demonstrate basic troubleshooting of control circuits.

1771.4.6    Install jogging and plugging circuits.

1771.4.7    Install reversing circuits.

1771.4.8    Demonstrate the use of a phase rotation meter.

Standard 5:  Apply knowledge and skills to relays.  (1771.S.5)

Relays Objectives

Students will:

1771.5.1    Describe and explain relays and relay circuits.

1771.5.2    Identify and install overload relays in control circuits.

1771.5.3    Identify and install potential-type relays in control circuits.

1771.5.4    Explain the difference between relay and magnetic starters.

1771.5.5    Explain troubleshooting techniques of relay and magnetic starters.

1771.5.6    Check various relays for faults or defects.

1771.5.7    Explain, check, and adjust various types of time delay relays.

Standard 6:  Differentiate between the different types of motor braking circuits.  (1771.S.6)

Motor Braking Circuits Objectives

Students will:

1771.6.1    Explain the various types of braking circuits for AC and DC motors.

1771.6.2    Describe dynamic braking circuits for AC and DC motors.

Standard 7:  Troubleshoot AC and DC motors.  (1771.S.7)

AC and DC Motors Objectives

Students will:

1771.7.1    Describe the various types of single-phase and three-phase AC motors and DC motors.

1771.7.2    Install, check, and troubleshoot various types of single-phase and three-phase motors in a circuit.

1771.7.3    Install, check, and troubleshoot various types of DC motors in a circuit.

Standard 8:  Demonstrate knowledge and skills related to alternators and generators.  (1771.S.8)

Alternators and Generators Objectives

Students will:

1771.8.1    List the major parts of an alternator and a generator and explain the function of each part.

1771.8.2    List and describe the different types of alternators and generators.

1771.8.3    Check alternators and generators for faults and defects.