Courses

Stationary Firer

**Course #: **Block X21
**Duration: **30 hours
**What Students Learn: **This module of six study units offers the trainee arithmetic and basic mathematics, metric measurement, and calculator fundamentals. The Metric System is an introductory unit which includes metric conversions. Problem exercises and examples in this module are presented in on-the-job scenarios with applications drawn from the industrial context.
**Components:** Addition and Subtraction (186008); Multiplication and Division (186009); Fractions, Percents, Proportions, and Angles (186010); Metric System (186011); Formulas (186012); Introduction to Algebra (186013);
**Special Notes:** This updated course replaces lessons contained within Practical Math and Measurements, Block X01. Each study unit contains a progress examination.

**Course #: **186008
**Duration: **5 hours
**What Students Learn: **

- Define the terms: whole number, numeral, digit, decimal, place value, addend, sum, minuend, subtrahend, and difference.
- Explain the significance of the digit zero in a number.
- Differentiate between concrete and abstract numbers.
- Properly prepare numbers for addition and subtraction.
- Perform addition and subtraction on numbers.
- How to check your answers to both addition and subtraction problems.
- How to use a calculator to add and subtract numbers.

**Course #: **186009
**Duration: **5 hours
**What Students Learn: **

**Course #: **186010
**Duration: **5 hours
**What Students Learn: **

**Course #: **186011
**Duration: **5 hours
**What Students Learn: **

**Course #: **186012
**Duration: **5 hours
**What Students Learn: **

**Course #: **186013
**Duration: **5 hours
**What Students Learn: **

**Course #: **Block X22
**Duration: **25 hours
**What Students Learn: **The five lessons in this block present the trainee with a broad overview of measurements found in an industrial setting. In addition to the basic measurements of length, temperature, energy, force, and power, the trainee will learn how materials are measured and handled in bulk quantities. Fluid measurements include the measuring of fluid flow, fluid pressure, and fluid level. All lessons include the metric conversions in addition to the English units.
**Components:** Temperature Measurement (186023); Linear and Distance Measurement (186021); Bulk Measurement (186022); Energy, Force, and Power (186024); Fluid Measurement (186025);
**Special Notes:** This updated course replaces the X0105 to X0109 lessons found in Practical Math and Measurements, Block X01. Each study unit contains a progress examination.

**Course #: **186021
**Duration: **5 hours
**What Students Learn: **

**Course #: **186022
**Duration: **5 hours
**What Students Learn: **

**Course #: **186024
**Duration: **5 hours
**What Students Learn: **

**Course #: **186025
**Duration: **5 hours
**What Students Learn: **

**Course #: **6632
**Duration: **10 hours
**Course Prerequisites:** Basic Industrial Math (Block X21);
**What Students Learn: **Introduction to Steam Generators; Water Tube Steam Boilers; Water Walls; Superheaters; Heat Recovery in Steam Generators; Industrial Applications of Steam Generators; Central Station Steam Generators; Types of Steam Generators - Marine Units, Waste-Heat Units, Packaged Boilers, Nuclear Units, and Hot Water Generators.

**Course #: **286091
**Duration: **10 hours
**What Students Learn: **Preview

Since the development of machinery, there has been a war against friction. Friction causes machinery to vibrate excessively, sound louder, use more energy to do a given job, and, most importantly, wear out faster. To counter friction, lubricants have been developed.

Lubricants were once basic animal fats and plant oils used on simple machines. Today's lubricants are chemical compositions specially designed for specific types of machines and their work environment. There are now hundreds of types of oils and grease to select from, each tailored specifically for the machine or an individual component of any given machine.

This study unit is designed to give students the information they need to understand how lubricants are blended into these very special compounds and how they are selected for various applications.

Objectives

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

Contents

Friction and Wear; The Purpose of Lubricants; How Lubricants are Classified; How Lubricants Work; Proper Lubricant Selection; Handling and Storing Lubricants Safely.

**Course #: **286092
**Duration: **10 hours
**What Students Learn: **Preview

Lubricating equipment is one of the most important industrial maintenance activities performed. Lubricants reduce friction, which saves on energy costs. They reduce wear, which saves on equipment maintenance costs. Proper lubrication significantly reduces machine downtime resulting from broken or worn out components. In addition, proper lubricating practices help keep a machine in tolerance for a longer period of time.

In today's world of twenty-four-hour-a-day, seven-days-a-week, plant operation, the role of lubrication takes on even greater importance. Equipment must be lubricated on a timely schedule, in the proper amounts, and with the correct lubricants to sustain long work cycles between planned shutdowns. This study unit will show you how to properly apply lubrication and maintain lubrication systems.

Objectives

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

Contents

Manual Methods of Lubrication; Lubricating Total-Loss Systems; Nonloss Lubrication Systems; Lubrication in Special Environments; Lubrication Conditioning; Automatic Lubrication Systems; Preventive and Predictive Lubrication Maintenance.

**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:

Contents

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

**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:

Contents

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

**Course #: **286015
**Duration: **10 hours
**What Students Learn: **Gears and Enclosed Gear Drives; Electric Motors; Maintenance of Gearing; Precision Chains and Chain Drives; Belt Drives; Correction for Shaft Misalignment; Clutches; Application Considerations for Mechanical Power Transmission.

**Special Notes:** This updated course replaces course 2606.

**Course #: **Block X02
**Duration: **72 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **This twelve lesson block is for those trainees requiring more advanced math subjects. The subject of algebra is covered in detail and the subjects of geometry and trigonometry are introduced in a practical manner.

Because math skills vary widely, a placement test is available to determine the trainee's specific knowledge of the various areas. Test X0250: Introduction to Algebra, Geometry, and Trigonometry is divided into four sections: lessons X0201 through X0204; lessons X0205 through X0208; lessons X0209 through X0210; and lessons X0211 and X0212.
**Components:** Algebra: Monomials and Polynomials (X0201); Algebra: Factoring (X0202); Algebra: Addition and Subtraction of Fractions (X0203); Algebra: Multiplication and Division of Fractions (X0204); Algebra: Linear Equations (X0205); Algebra: Simultaneous Linear Equations (X0206); Algebra: Determinants (X0207); Algebra: Quadratic Equations (X0208); Algebra: Exponents (X0209); Algebra: Radicals and Imaginary Numbers (X0210); Applied Geometry (X0211); Practical Trigonometry (X0212); Progress Examination Booklet (X0220); Progress Examination (X0221); Progress Examination (X0222); Progress Examination (X0223); Progress Examination (X0224); Placement Test: Introduction to Algebra, Geometry, and Trigonometry (X0250);

**Course #: **X0201
**Duration: **6 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **

**Course #: **X0202
**Duration: **6 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **

**Course #: **X0203
**Duration: **6 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **

**Course #: **X0204
**Duration: **6 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **

**Course #: **X0205
**Duration: **6 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **

**Course #: **X0206
**Duration: **6 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **

**Course #: **X0207
**Duration: **6 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **

**Course #: **X0208
**Duration: **6 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **

**Course #: **X0209
**Duration: **6 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **

**Course #: **X0210
**Duration: **6 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **

**Course #: **X0211
**Duration: **6 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **

**Course #: **X0212
**Duration: **6 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **

**Course #: **5011
**Duration: **10 hours
**Course Prerequisites:** Practical Measurements (Block X22);
**What Students Learn: **Chemistry and Matter; Chemical and Physical Changes; Chemical Classification of Matter, Elements, Compounds, Mixtures; Atoms and Molecules; Dalton's Atomic Theory; Atomic Weights; Molecular Weights; Electron Theory of the Structure of the Atom; Study of Electrons, Protons, Neutrons, Atomic Structure of Elements; Fundamental Laws of Chemistry; Laws of Conservation of Matter and Energy; Law of Definite Proportions; Valence Formulas; Equations; Typical Problems in Chemistry; Solutions; Metals, Nonmetals, Acids, Bases, and Salts; Ions and Theory of Ionization; Conductivity, pH, Electrolysis, Electroplating; Periodic Grouping of the Elements; Properties and Uses of Metallic and Nonmetallic Elements and Their Compounds; Nuclear Energy; Organic Chemistry; Structural Formulas, Hydrocarbons, Fatty Acids, Carbohydrates, Aromatic Compounds, Plastics.

**Course #: **686001
**Duration: **10 hours
**Course Prerequisites:** Logarithms (5254); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
**What Students Learn: **The Nature of Heat; Temperature and its Measurement; The Measurement of Quantity of Heat; Expansion and Contraction; Change of State; Transfer of Heat; Heat and Work Relationships.

**Special Notes:**

**Course #: **686002
**Duration: **10 hours
**Course Prerequisites:** Logarithms (5254); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
**What Students Learn: **Relationship between Pressure, Volume, Temperature, Weight of Gases, and the Gas Constant; Expansion of Gases; Compression of Gases; Closed Cycles; Carnot's Engine.

**Special Notes:**

**Course #: **5254
**Duration: **10 hours
**Course Prerequisites:** Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **Table of Common Logarithms; Table of Useful Numbers; Exponents; Logarithms of Numbers; Determination of Characteristics of a Logarithm; Determination of Mantissa of a Logarithm; Proportional Parts; Determination of Antilogarithms; Multiplication by Use of Logarithms; Division by Use of Logarithms; Finding Powers and Roots by Logarithms; Cologarithms; Hyperbolic Logarithms.

**Course #: **286007
**Duration: **10 hours
**Course Prerequisites:** Practical Geometry and Trigonometry (5567); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **Matter and Energy; Scope of Mechanics; Forms of Matter; Forms of Energy; Physical Properties of Bodies; Motion of Bodies; Velocity; Acceleration and Retardation; Weight and Mass; Work and Energy; Coordinate Systems; Precision in Computations; Newton's Laws of Motion; Uniform Motion; Variable Motion.

**Special Notes:**

**Course #: **286008
**Duration: **10 hours
**Course Prerequisites:** Practical Geometry and Trigonometry (5567); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
**What Students Learn: **Friction; Nature of Friction; Sliding Friction; Rolling Friction; Machine Elements; Levers; Inclined Plane; Wedges and Screw Threads; Wheel and Axle; Tackle; Pulleys; Gearing; Belts and Chains; Simple Harmonic Motion Centrifugal Force.

**Special Notes:**

**Course #: **286010
**Duration: **10 hours
**Course Prerequisites:** Plane Trigonometry (2309A-B); Logarithms (5254); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
**What Students Learn: **Physical Properties of Fluids; Intensity of Pressure; Water Pressures on Simple Immersed Surfaces; Buoyancy; Specific Gravity of Solids; Flow of Liquids Through Pipes; Losses of Head in Pipes; Bernoulli's Theorem; Venturi Meters.

**Special Notes:**

**Course #: **2620
**Duration: **10 hours
**Course Prerequisites:** Logarithms (5254); Heat, Part 1 (686001); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
**What Students Learn: **Theory of Vaporization; Saturated Steam; Temperature-Heat Diagram; Generating Steam Heat Required for Evaporation at Different Pressures; Steam Tables; Definition of Entropy; Calculation of Change of Entropy; Use of Super-Heated Steam Table; Use of Mollier Heat Chart.

**Course #: **2585
**Duration: **10 hours
**Course Prerequisites:** Types of Steam Generators (6632); Practical Measurements (Block X22);
**What Students Learn: **A.S.M.E. Boiler Code; Safety Valves; Water Level Indicating Equipment; Steam Gages; Steam Generator Piping Systems and Valves; Soot Blowers; Air Preheaters; Dust Collectors; Monitoring Equipment; Sealing Systems.

**Course #: **2598A-B
**Duration: **20 hours
**Course Prerequisites:** Steam (2620); Logarithms (5254); Types of Steam Generators (6632); Heat, Part 1 (686001); Heat, Part 2 (686002); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
**What Students Learn: **PART 1 (2598A). Purpose of Steam Generators; Utility Company Boilers; Industrial Boilers; Design Considerations.

PART 2 (2598B). Conduction Heat Transfer; Thermal Conductivities of Common Steam Generator Materials; Radiant Heat Transfer; Radiation in Furnaces; Heat Balance for Steam Generator Furnaces; Convection Heat Transfer; Convection Equation for Cross Flow; Longitudinal Flow of Gases and Steam-Film Resistance; Combined Heat Transfer Modes.

**Course #: **2587
**Duration: **10 hours
**Course Prerequisites:** Types of Steam Generators (6632);
**What Students Learn: **General Considerations of Steam Generator Settings; Materials Used in the Construction of Setting; Insulation for Refractory; Construction of the Setting; Design of the Setting; Preparing the Setting for Operation; Proportions of the Furnace; Ash-Removal Systems; Testing the Setting; Flues and Ducts; Draft; Stacks.

**Course #: **6727
**Duration: **10 hours
**Course Prerequisites:** Elements of Chemistry (5011); Practical Measurements (Block X22);
**What Students Learn: **Common Impurities Found in Feedwater; Types of Treatment; Boiler Feedwater; Regulating the Flow of Feedwater; Heating; Chemical Feeding; Testing of Feedwater.

**Course #: **6473
**Duration: **10 hours
**Course Prerequisites:** Practical Measurements (Block X22);
**What Students Learn: **Principles of Solid Fuel Burning; Methods of Fixing; Types of Grates; Mechanical Stokers; Waste Fuel Firing; Principles of Pulverized Coal Burning; Pulverized Coal Installations; Auxiliary Equipment; Steam Generator Design Features for Pulverized Coal Burning; Operation of Pulverized Coal Installations.

**Course #: **2592
**Duration: **10 hours
**Course Prerequisites:** Elements of Chemistry (5011); Fuels (5340); Practical Measurements (Block X22);
**What Students Learn: **Fuels; Boiler Elements; Oil Firing; Gas Firing; Operating Procedures; Start-Up and Shutdown Procedures; Troubles and Remedies; Maintenance Lighters; Safety and Efficiency.

**Course #: **6810
**Duration: **10 hours
**Course Prerequisites:** Elements of Chemistry (5011); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
**What Students Learn: **Factors Affecting Efficiency; Constituents of Flue Gas; Methods of Analysis; Effects of Excess Air; Causes of Carbon Monoxide Formation and Prevention; Methods of Sampling; Types of Gas-Analyzing Equipment; Oxygen Analyzers; Carbon Dioxide Analyzers; Miscellaneous Analyzers; Auxiliary Apparatus.

**Course #: **6802
**Duration: **10 hours
**Course Prerequisites:** Steam (2620); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
**What Students Learn: **Performance Tests; Steam Purity; Steam Temperature; Sampling and Analysis of Refuse; Combustion Air and Flue Gas Weight; Air Leakage; Steam Generator Efficiency.

**Course #: **6472
**Duration: **10 hours
**Course Prerequisites:** Practical Measurements (Block X22);
**What Students Learn: **Sampling Solid Fuels; Methods of Sampling; Determining and Calculating Moisture Content; Laboratory Testing of Samples; Classification and Basic Characteristics of Liquid Fuels; Metering and Tank Gaging; Collection of Samples; Sampling Methods and Devices; Laboratory Processes.

**Course #: **2596A-C
**Duration: **30 hours
**Course Prerequisites:** Types of Steam Generators (6632); Practical Measurements (Block X22);
**What Students Learn: **PART 1 (2596A). Preliminary Considerations; Types of Combustion Control; Steam Applications; Hot-Water Applications; Feedwater and Draft Controls; Cashco Combustion Controller.

PART 2 (2596B). Operation of Bailey Automatic Combustion Controller; Operation of Hagan Automatic Combustion Controller; Operation of Beckman-Republic Control System.

PART 3 (2596C). Control System Diagramming; Operation of Bailey Electronic Control System; Hagan Electronic Combustion Control System Applied to a Central Power Generating Station; Operation of Leeds & Northrup Electronic Combustion Control System; Comparison between Pneumatic and Electronic Control Systems.
**Components:** Automatic Combustion Control, Part 1 (2596A); Automatic Combustion Control, Part 2 (2596B); Automatic Combustion Control, Part 3 (2596C);

**Course #: **2514
**Duration: **10 hours
**Course Prerequisites:** Practical Measurements (Block X22);
**What Students Learn: **Basic Definitions; Factors Affecting Power Rates; Factors Affecting Power Plant Design; Design of Plant and Purchase Lists; Initial Starting and Testing Plan; Energy Rates; Heat Exchangers; Air and Heat Pollution; Development of Mine-Mouth Power Plants; Power Pooling.

**Course #: **286001
**Duration: **10 hours
**Course Prerequisites:** Hydraulic Components: Actuators, Pumps, and Motors (286061);
**What Students Learn: **Modern Centrifugal Pumps; Operating Principles of Pumps; Classifications and Types of Pumps; Fundamental Pump Terms: pressure, vapor pressure, head, losses, cavitation, net positive suction head, specific speed, viscosity; Centrifugal Pump Performance Curves; Types of Pumping System Curves.

**Special Notes:**

**Course #: **286002
**Duration: **10 hours
**Course Prerequisites:** Hydraulic Components: Actuators, Pumps, and Motors (286061);
**What Students Learn: **Construction details of Centrifugal Pumps; Applications of Centrifugal Pumps; Installation and Maintenance of Centrifugal Pumps; Troubleshooting problems associated with Centrifugal Pump Operation.

**Special Notes:**

**Course #: **286003
**Duration: **10 hours
**Course Prerequisites:** Hydraulic Components: Actuators, Pumps, and Motors (286061);
**What Students Learn: **Rotary Pumps: classifications, installation and operating principles; Reciprocating Pumps: classifications, installation and operating principles; Power Pumps; Applications of Rotary and Reciprocating Pumps; Troubleshooting Rotary and Reciprocating Pumps.

**Special Notes:**

**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:**

**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:**

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