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Optional: Mechanical Systems Operations and Maintenance

Mechanical Testing of Materials

Course #: 2608A-B
Duration: 20 hours
Course Prerequisites: Practical Measurements (Block X22);
What Students Learn: PART 1 (2608A). Purpose of Testing Physical Properties of Materials; Mechanical Testing Machines; Tension Test; Compression Test.
PART 2 (2608B). Transverse or Beam Test; Shear and Torsion Tests; Hardness Testing, Impact Testing; Miscellaneous Tests for Ductile Materials; Testing of Nonmetals.

Air Compressors, Part 1

Course #: 286013
Duration: 10 hours
Course Prerequisites: Metric System (186011);
What Students Learn: Types of Compressors; Types of Comparison; Centrifugal Compressors; Axial-Flow Compressors; Construction Details of Centrifugal and Axial-Flow Compressors; Performance Curves; Installation and Performance Tests.

Special Notes:

  • This updated course replaces course 2626A.
  • The entire course consists of study units 286013-286014.

    • Air Compressors, Part 2

    Course #: 286014
    Duration: 10 hours
    Course Prerequisites: Metric System (186011);
    What Students Learn: Reciprocating Compressors; Cylinder and Piston Arrangements; Construction Details of Various Types; Selection, Installation, and Operation of Reciprocating Compressors; Rotary Compressors; Construction Details; Lobe Compressors; Screw Compressors; Troubleshooting Rotary Compressors.

    Special Notes:

  • This updated course replaces course 2626B.
  • The entire course consists of study units 286013-286014.

    • Bearings and Seals, Part 1

    Course #: 286093
    Duration: 10 hours
    What Students Learn: Preview
    Bearings of one type or another have been used since the invention of the most primitive machines. Bearings support rotating machine shafts as well as translating movement in machine components, and bearings keep the components in correct alignment.

    This study unit, will primarily discuss plain bearings. However, so that students understand the fundamental differences, it will briefly cover antifriction bearing operation. Students will get a basic understanding of the differences between plain bearings and antifriction bearings. The study unit will then discuss the various types of plain bearings and their uses in greater detail.

    Because bearings are used in such a wide range of applications, there are many factors to consider when selecting a bearing for a specific need. It is important that students understand these factors and the process for choosing the correct bearing and lubrication method for an intended application. In this study unit, students will also learn about the different techniques and tools used to properly install, lubricate, and remove bearings.

    Objectives
    When a student completes this study unit, he and she will be able to:

  • Understand what friction is and how bearings help reduce it.
  • Explain the difference between plain and antifriction bearings.
  • List the different types of plain bearings.
  • Understand the characteristics of plain bearings.
  • Know the importance of proper handling and installation of bearings.
  • Recognize the importance of proper bearing lubrication.
  • List the different materials used to make plain bearings and how material type affects their use.
  • Explain how to prevent premature bearing failure.

    Contents
    Introduction to Bearings; Journal Bearings; Other Types of Plain Bearings; Installing and Maintaining Plain Bearings; Plain Bearing Failure.

    Special Notes: This updated course replaces 2602.

    • Bearings and Seals, Part 2

    Course #: 286094
    Duration: 10 hours
    What Students Learn: Preview
    Bearings and seals are used in most every type of machine. This study unit will help you learn how to identify, lubricate, maintain, and replace antifriction bearings and seals.

    As students know, there are two types of bearings, plain and antifriction. Plain bearings use a sliding motion to reduce friction, while an antifriction bearing contacts the shaft it supports with a rolling element. This rolling motion helps reduce friction. The rolling motion produces less friction than the sliding motion produced from plain bearings. Therefore, the rotation of a shaft is smoother with an antifriction bearing.
    In this study unit, students will learn about the various types of antifriction bearings and their different parts. They will also learn about the basic characteristics of these bearings, and how to apply them to a particular shaft. The study unit will also cover proper installation and maintenance and properly applying them. An important part of proper application is correctly combining the various materials available in bearings with the material the shaft is made from.

    This study unit will also help students better understand seals. They will learn what a seal does, the different types of seals available, and how they are used. Students will also learn; the various types of material that seals are manufactured from, their advantages, the importance of maintaining bearings, and how to replace seals when they fail.

    Objectives
    When a student completes this study unit, he and she will be able to:

  • Identify the various elements used in antifriction bearings.
  • Properly identify and correct problems in antifriction bearings.
  • Choose the proper seal.
  • Choose and apply the proper lubricants for seals and antifriction bearings.
  • Understand the need for clearance and tolerances in bearings.
  • Identify the various parts of a seal.

    Contents
    Antifriction Bearings; Antifriction Bearing Replacement; Maintaining Antifriction Bearings; Installing and Maintaining Lip Seals.

    Special Notes: This updated course replaces 2602.

    • Predictive Maintenance

    Course #: 286087
    Duration: 5 hours
    Course Prerequisites: Trades Safety: Getting Started (186001); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
    What Students Learn: Preview
    Predictive technologies measure one or more characteristics of machine operation, calculate the expected life of the monitored system, and then estimate the condition of equipment and, therefore, the need for maintenance on that equipment. With this information passed along to a good preventive maintenance program, the preventive maintenance team can make informed decisions on task scheduling and make the most of its maintenance and inspection tasks.

    Vibration analysis programs are the most commonly conducted PDM efforts. By performing inspection and repairs during downtime, uptime failures of the analyzed components are all but eliminated. PDM is more than vibration analysis, however; multiple technologies, such as infrared thermography, balance, alignment, and electrical signature analysis are part of many PDM programs. Because of these technologies, plants run better and are more competitive. PDM allows maintenance departments to predict when a unit will fail and plan its maintenance during a scheduled downtime, usually when the unit is cooler, cleaner, and not needed for the manufacturing process.

    Objectives
    When a student completes this study unit, he and she will be able to:

  • Define what PDM is and how it can be used in industry.
  • Identify the various types of technologies used in PDM.
  • Explain what goals should be considered for a new and a maturing PDM program.
  • Discuss the scope of basic mechanical PDM.
  • Explain how a time waveform and a frequency spectrum can be used to identify machine faults.

    Contents
    What Is Predictive Maintenance?; Predictive Maintenance Program Goals; Basic Mechanical Predictive Maintenance; Forms Of PDM Data.

    • Predictive Maintenance: Vibration Analysis

    Course #: 286088
    Duration: 5 hours
    Course Prerequisites: Trades Safety: Getting Started (186001); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
    What Students Learn: Preview
    When a company decides to begin a predictive maintenance (PDM) program, the first technology usually embraced is vibration analysis. Vibration analysis allows the technicians or other specially trained personnel to perform condition monitoring of equipment. Condition monitoring is used at first as a coarse comb to pull out those programs that will imminently cause downtime. Then the program can progress beyond condition monitoring to provide scheduling services for preventive maintenance and identification of redesigns that address repetitive faults.

    This study unit will show you the basics of vibration analysis as performed with a data collector and a computer software program. These devices will be used to collect vibration measurement data and to store and display the results.

    Objectives
    When a student completes this study unit, he and she will be able to:

  • Explain how vibration measurements are taken and the systems used to identify measurement points.
  • Identify balance, looseness, and misalignment problems.
  • Discuss the techniques used to diagnose rolling-element bearing faults.
  • Explain how journal bearing condition monitoring and fault analysis is performed.
  • Identify speed reducer faults that occur in the gear sets or the internal bearings.
  • Describe how resonance can affect the operation of equipment.

    Contents
    Vibration Measurements; Analyzing Balance And Looseness Problems; Misalignment Of Inline And Overhung Drive Systems; Analyzing Rolling-Element Bearing Systems; Condition Monitoring Of Journal Bearings; Condition Monitoring Of Speed Reducers; Resonance.

    • Predictive Maintenance: Advanced Topics

    Course #: 286089
    Duration: 5 hours
    Course Prerequisites: Trades Safety: Getting Started (186001); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
    What Students Learn: Preview
    Vibration analysis alone cannot perform sufficient condition monitoring to meet the needs of today's industry. Vibration analysis cannot easily find electrical faults, air leaks, electrical discharges, metal particles or contamination and breakdown of lubricants, or other important monitoring processes. Other technologies are needed for these tasks. This study unit will introduce you to these other technologies.
    In this study unit, we will investigate many different technologies that can and should often be part of a good predictive maintenance program (PDM). This course is designed to discuss these technologies at a basic level. If you're considering working with one of these technologies, it's very important to understand how to operate the equipment involved and to gain additional equipment training from the manufacturer. These actions will provide you with a safe and profitable expanded PDM program.

    Objectives
    When a student complete this study unit, he and she will be able to:

  • Explain the steps involved in performing balance and alignment on industrial machines.
  • Discuss the use and operation of ultrasonic equipment to find problems such as electrical arcing, bearing faults, and internal and external air leaks in pneumatic systems.
  • Describe the procedures used in electrical signature analysis (ESA) and how this inspection system can find motor problems.
  • Explain how oil analysis can find lubricant problems and contamination.
  • Describe how thermography can be used in a PDM environment.

    Contents
    Modern Balance And Alignment; Ultrasonic Testing; Electrical Signature Analysis; Oil Analysis; Infrared Thermography.

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