Mechanical Machines Maintenance Technology

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Page 1 of 64 ش

Semesters

1439 H – 2018 G

TECHNOLOGY DIPLOMA Curriculum for Department of

Mechanical Machines Maintenance Technology

Major

Management Technology

Training Plans For Technical Colleges

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Page 2 of 64

Introduction

Praise be to Allah who taught (the use of) the pen, Taught man that which he knew not. Peace and blessings upon our Prophet, instructor and role model, Muhammad Ibn Abdullah, who is sent as a teacher and guide to people and caller to Allah to bring people out of the darkness of ignorance and misguidance to the light of knowledge and guidance.

The Technical and Vocational Training Corporation seeks to qualify trained national cadres who are able to fill technical, technical and vocational jobs available in the Saudi labor market. This interest comes as a result of the directions requested by the leaders of this country. All these jobs seek to obtain an integrated homeland that depends first on Allah's success, then on its resources and the strength of its youth, which has knowledge and faith. Everyone strives for the sake of continuing to reach developmental progress, so that, by the grace of Allah, the country becomes one of the highest industrialized countries.

The Director General for curricula has taken a positive step in line with advanced international experiences to build training programs, according to modern scientific methods that are compatible with the requirements of the labor market in all its specialties to meet these requirements. This step consisted of the National Professional Standards Preparation Project, then the National Professional Qualifications Project. Both projects are the main pillar in building training programs. Standards and qualifications depend on the formation of specialized committees representing the labor market and the General Organization for Technical and Vocational Training. The scientific vision must be compatible with the practical reality imposed by the requirements of the labor market, so that these committees ultimately come out with an integrated view of a training program more relevant to the labor market, and more realistic in achieving its basic requirements.

This training plan deals with the "insurance plan" in the Department of Management Technology for trainees of technical colleges to describe the courses of this specialization. This plan needs to include vital Subjects that deal with how to acquire the necessary skills for this specialization so that their skills are to assist them in their practical life after graduating from this program.

The Director General for curricula hopes that this training plan will be a direct contribution to the study of necessary skills, in a simplified manner free of complication.

We hope that Allah will grant success to those who prepare the training plan and its beneficiaries, for what Allah wants and pleases.

Director General for curricula

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Page 3 of 64 Table of Content

No Subject Page

1 Introduction 2

2 Index 3

3 Program description 4

 Program description

 The overall goal of the program

 The detailed objectives of the program

4 Distribute the training plan to the training classes 5

5 Cover brief description of specialized training courses 7

6 Brief description of specialized training courses 8

7 Cover detailed description of major courses 9

8 Basics of the fluid mechanics 10

9 Maintenance of mechanical elements 1 14

10 Maintenance of mechanical elements 2 19

11 Workshop and welding technology 24

12 Maintenance of mechanical systems 29

13 Electro-mechanical machinery 34

14 Rotary machines 1 39

15 Rotary machines 2 43

17 Vibration and balance 47

18 Cover of appendices of the training plan 51

19 Summary of equipment, human resources and capacity 52

20 A statement of the laboratories, workshops and laboratories 53

21 Equipment science laboratory 54

22 Mechanical components maintenance workshop equipment 55

23 Mechanical systems maintenance workshop equipment 56

24 Electrical and electronics workshop equipment 57

25 Turntable workshop equipment 59

26 Vibration and stability laboratory equipment 59

27 Appendix on the proposed evaluation tools 60

28 References 63

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Page 4 of 64 Program Description

The diploma in mechanical machinery maintenance in the Department of Mechanical Technology was designed in accordance with the needs of the local labor market for specialization. Training in this specialization is carried out in technical colleges in five semester training classes, the duration of each training semester eighteen training weeks, with a total of (1712) training hours, in addition To (490) hours practical training in the labor market, equivalent to (79) credit hours.

Training in this program is carried out on specialized skills in: measurements, engineering drawing, computer aided drawing, CAD science, materials science, workshop and welding technology, maintenance of mechanical elements and systems, the basics of pneumatic and hydraulic control, and rotating machines, and the program also addresses fluid mechanics and vibrations and Equilibrium, electrical and electronics mechanical machinery, as well as general skills in Islamic culture, Arabic, English, mathematics, physics and computer applications, career guidance, excellence, job behavior and communication skills.

A graduate of this program is granted an intermediate university certificate in the field of mechanical machinery maintenance from the Department of Mechanical Technology, and it is expected that he will work in industrial fields in mechanical machinery maintenance

The overall objective of the program

This program aims to provide the trainee with the skills and information necessary to practice work in the mechanical field and gets a fifth level in the national qualifications framework

The detailed objectives of the program

By the end of this program, the trainee will be able to:

 To follow the correct safety procedures in the field of work.

 Preparing the workplace.

 Choose and use the appropriate number and maintenance tools.

 Carry out periodic maintenance procedures and carry out repairs

 Replace the damaged parts.

 Installing parts and machines and performing balancing operations.

 Operate production workshop machines

 Preparing reports in the field of specialization.

 Participate in developing business methods.

 Planning the training process.

 Developing his technical and practical experiences.

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The Study Distributed on Semesters

1 st Semester

No Course Code Course Name Prerequisites Equivalent No of unites

CRH L P T CTH

1 ARAB 101 Technical Writing ARB 101 2 2 0 0 2

2 ENGL 101 English Language -1 ENG 8101 3 3 0 1 4

3 PHYL 101 Physics PHY 8101 3 2 2 1 5

4 MAT 121 Mathematics MAT 115 3 3 0 1 4

5 VOCA 101 Vocational Guidance &

Excellence

VOC 107 2 2 0 0 2

6 MMEC 101 Preparatory Workshop MEC 162 2 0 4 0 4

7 MMEC 141 Measurements MEC 163 3 2 2 0 4

Total Number of Units 18 14 8 3 25

CRH: Credit Hours L: Lecture P: Practical T: Tutorial CTH: Contact Hours

2 st Semester

No Course

Code Course Name Prerequisites Equivalent No of unites

CRH L P T CTH

1 ISLM 101 Islamic Studies ISL 101

ISL 102

2 2 0 0 2

2 ENGL 102 English Language -2 ENG 101 ENG 8102 3 3 0 1 4

3 ICMT 101 Introduction to Computer Applications

CMT 101 2 0 4 0 4

4 MMEC 131 Engineering Drawing MEC 111 2 0 4 0 4

5 MMAIN

151

Maintenance of Mechanical Elements -1

MMEC 101 MMEC 141

MAIN 173 4 2 4 0 6

6 MMEC 145 Materials Science MEC 174 3 3 2 0 4

7 MMAIN

141

Basics of Fluid Mechanics PHYS 101 MAIN 171 3 2 2 0 4

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3 st Semester

CRH L P T CTH

1 LEAS 101 Learning Skills 2 2 0 0 2

2 ENGL 103 English Language -3 ENGL 102 ENG 8103 3 3 0 1 4

3 MMIN 171 Workshop Technology & Welding MMEC 101 MMEC 141

WAIN 175 4 2 4 0 6

4 MMEC 121 Fundamentals of Pneumatic and Hydraulic Control

PHYS 101 MEC 9261 3 2 2 0 4

5 MMIN 252 Maintenance of Mechanical Elements -2

MMIN 151 MAIN 174 4 2 4 0 6

6 MMIN 261 Rotating Machinery -1 MMIN 141

MMIN 151

MAIN 266 4 2 4 0 6

4 st Semester

CRH L P T CTH

1 ETH 101 Professional Ethics & Comm. Skills VOCA 101 ETH 101 2 2 0 0 2

2 MMEC 233 CAD: Computer Aided Drawing MMEC 131 MEC 9251 2 0 4 0 4

3 MMIN 253 Maintenance of Mechanical Systems MMEC 101 MMEC 141

MAIN 251 4 2 4 0 6

4 MMIN 221 Electricity & Electronics of Mechanical Machines

PHYS 101 MAIN 9252 3 2 2 0 4

5 MMIN 262 Rotating Machinery -2 MMIN 261 MAIN 267 4 2 4 0 6

6 MMIN 264 Machinery Vibration MMIN 261 MAIN 9264 3 2 2 0 4

5st Semester

No Course Code Course Name No of unites

CRH

1 MAIN 299 Co-operative Training 4

Total Number of Units 4

CRH: Credit Hours L: Lecture P: Practical Hours T: Tutorial CTH: Contact Hours

Total Number of Semesters Credit Unites CRH L P T CTH

79 48 54 5 107

Total of training Hours (16×107 )+ Cooperative training Hours (490 2202

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Brief description of the major courses

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Page 8 of 64 Course

Name

Fundamentals of Fluid Mechanics

Course

Code 141 MAIN CRH 3

Description

This course introduces the trainee to the basic elements of fluid properties and deals with static and fluid dynamics. It also provides calculations for the flow in pipes and ducts and pressure loss due to friction. The course also presents the basic laws governing fluids.

Course Name

Maintenance of mechanical elements (1)

Course

Description

This course provides the trainee with the theoretical and practical bases for maintenance of some of the most important elements of mechanical machines, bearings of various types, lubrication, lubrication, couplers and spindles (monitoring and parallel adjustment).

Course Name

Maintenance of mechanical elements (2)

Course

Description

This course complements the previous course (Maintenance of Mechanical Elements) (1) and provides the trainee with the theoretical and practical bases for maintenance of some of the most important elements of mechanical machinery, namely leaks, chains, belts, gears, and transmissions with variable speeds

Course Name

Workshop and welding technology

Course

Description

This course provides the trainee with the theoretical and practical foundations in operating production and welding workshop machines and the necessary technical skills in the field of mechanical machinery maintenance.

Course Name

Maintenance of mechanical systems

Course

Description

This course provides the trainee with the theoretical and practical foundations for the maintenance of some common mechanical systems in the industry, such as cranes of all types, balance, tubes and valves of all kinds, methods of operation and maintenance. It also displays types of boilers, heat exchangers, Vapor traps and their maintenance methods

Course Name

Electro-mechanical machinery

Course

Description

This course introduces the trainee the theoretical and practical foundations of electrical and electronic technology through the definition of the basic laws in electricity and electronics and the definition of basic electrical and electronic elements and their installation in different departments and their practical applications (electric motors and control boxes).

Course

Name Rotary machines (1) Course

Description This course provides the trainee with the theoretical and practical bases for identifying the different types of pumps, their uses, and their maintenance methods.

Course

Name Rotary machines (2) Course

Description This course provides the trainee with the theoretical and practical bases to get acquainted with all kinds of compressors, fans and turbines, and their maintenance methods.

Course

Name Vibration and balance Course

Description

This course introduces to the trainee the theoretical and practical foundations of vibrations and equilibrium, starting with the definition of vibrations, their causes, the devices used in measuring vibrations, the use of vibrating monitoring systems, and the analysis of results. The course is also known as static and dynamic equilibrium methods, as well as the equilibrium methods for rotating and reciprocating machines.

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Page 9 of 64

Detailed description of the major courses

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Name Basics of the fluid mechanics Course

Code MAIN 141

Prerequisite 101 PHY

Training semester 1 2 3 4 5

Credit hours 3

Collaborative training Contact hours

(Hour/ week)

Session 2

Practical 2

Training 0

Course Description

This course introduces the trainee to the basic elements of fluid properties and deals with static and fluid dynamics. It also provides calculations for the flow in pipes and ducts and pressure loss due to friction. The course also presents the basic laws governing fluids

The general objective of the course:

Giving the trainee the basics of fluid mechanics that help him analyze the performance of fluid mechanical machines.

The detailed objectives of the course:

First: cognitive goals:

The trainee should be able to:

1. Hydrostatic laws applied (static fluid pressure).

2. Determine the difference between dynamic and kinematic viscosity.

3. Set pressure for the fluid using different manometers.

4. Application of the continuity equation and Bernoulli equation to an open system.

5. Explain the coefficient of friction and calculation of pressure drop in tubes, air ducts and connections.

Second: procedural goals:

1. Calculation of pressure in static fluids.

2. Find the fluid pressure using different manometers.

3. Calculate the flow rate and pressure difference.

4. Calculation of pressure drops in pipes, ducts and connections.

5. Calculation of forces from fluid pressure.

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Page 11 of 64

Units (theoretical and practical) Training hours Theoretical practical

Physical properties of fluids 6 6

Fluid statics 6 8

Fluid dynamics 10 12

Flow and pressure drop in tubes and air ducts 8 8

Total 32 32

64

Safety procedures and requirements:

1. The trainee follows the safety and security procedures in the lab.

2. The apprentice puts the tools in the right place.

3. The trainee avoids the sharp edges of tools and devices.

4. The trainee shall keep the place clean, and appropriate lighting.

5. The trainee wears protective equipment (glasses, shoes, hat, masks, etc.) 6. Handle cautiously with high pressure, heat and electricity.

7. Use caution with oils and other fluids in the lab.

The detailed approach (theoretical and practical)

hours Content Assessment tools

12

Physical properties of fluids:

 introduction

 Fluid density

 Specific gravity of the fluids

 Viscosity

o Exercises and exercises o Fluid properties

o Viscosity

o Carrying out practical viscosity experiments o Writing reports and drawing conclusions

Oral tests And written tests Practical performance

Subject

references 1. Fundamentals of Fluid Mechanics, G. S. Sawhney, 2011, Pages 1-60

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Page 12 of 64

14

Fluid statics:

 Torricelli's Law

 Archimedes' Law

 Measured pressure

 Absolute pressure

 Hydrostatic pressure

 Methods and devices for measuring pressure o Exercises and exercises

o Torricelli's Law o Archimedes' Law

o Types of pressure and ways to measure them o Measured pressure

o Absolute pressure o Hydrostatic pressure

o Methods and devices for measuring pressure

Subject references

1. Fundamentals of Fluid Mechanics, G. S. Sawhney, 2011, Pages 64- 230.

22

Fluid dynamics:

 Fluid flow

 Continuity equation

 Bernoulli's equation

 Bernoulli equation applications Exercises and exercises

o Fluid flow

o Continuity equation o Bernoulli's equation

o Bernoulli equation applications

Subject references

1. Fundamentals of Fluid Mechanics, G. S. Sawhney, 2011, Pages 310- 580.

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Page 13 of 64

16

Flow and pressure drop in tubes and air ducts:

 Laws of hypotension

 Coefficient of friction

 Moody outline

o Exercises and exercises

o Exercises to calculate stress and use the Moody chart

Subject references

1. Fluid Mechanics Fundamentals and Applications, Yunus Cengel, John Cimbala, 2013.

References

1. Fundamentals of Fluid Mechanics, G. S. Sawhney, 2011.

2. Fluid Mechanics Fundamentals and Applications, 3rd Edition 2013, by Yunus Cengel, John Cimbala.

3. Fundamentals of Fluid Mechanics,7th Edition, by Bruce R. Munson, Alric P.

Rothmayer, Theodore H. Okiishi, Wade W. Huebsch.

4. Engineering Fluid Mechanics, 10th Edition, by Donald F. Elger, Barbara C. Williams, Clayton T. Crowe, John A. Roberson.

5. Fluid Mechanics, 1st Edition 2015, by Russell C. Hibbeler.

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Name Maintenance of mechanical elements 1 Course

Code MAIN 151

Prerequisite 101 PRO 141 PRO

Credit hours 4

(Hour/ week)

Session 2

Practical 4

Training 0

This course provides the trainee with the theoretical and practical bases for maintenance of some of the most important elements of mechanical machines, bearings of various types, lubrication, lubrication, couplers and spindles (monitoring and parallel adjustment).

This course aims to provide the trainee with maintenance skills, the most important mechanical elements commonly used in the industry.

First: cognitive goals:

1. Learn about the types of mechanical equipment, designs and work methods.

2. Carrying out preventive and periodic maintenance of mechanical equipment.

3. Identify equipment malfunctions and problems.

4. Dismantle and install equipment.

5. Carrying out maintenance of mechanical equipment Second: procedural objectives:

1. Removal, installation, inspection and maintenance of bearings.

2. Carry out appropriate lubrication and lubrication.

3. Dismantling, installing, checking and selecting suitable couplers and spindles.

Bearings 28 14

Lubrication and lubrication 12 6

Couplings and spindles 24 12

Total 64 32

96

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Page 15 of 64 Safety procedures and requirements:

The trainee is keen on the safety and security procedures followed in the maintenance workshops so he puts the tools in their right place and are keen on avoiding the sharp edges of the tools and devices, as well as the cleanliness of the place, appropriate lighting and wearing protective equipment (glasses, shoes, hat, masks, etc.). The trainee must also Follow the instructions of the trainer and do not perform experiments or disassemble and install except under the supervision of the trainer.

42

Theoretical detailed bearings approach:

 Analysis of the principle of friction and rolling.

 Definition of bearing functions.

 Know the types of plain and rolling bearings.

 Know the methods of installing and installing rolling bearings "X" and "O".

 Enumeration conditions for selection of bearings:

example spherical bearings.

 Selection of bearings through manufacturers' catalogs.

 Knowing the methods of cold installation, adjustment and installation of bearings.

 Know the methods of installing, adjusting and installing the bearings by heating.

 Know the types of bearings damage, their causes and available solutions.

 Calculation of life span of bearings: spherical bearings example.

 Explanation of the principle of operation of partial arc and inclined pillow bearings.

 Knowing the types of damage, its causes and available solutions.

 Find out ways to install, modify, and install it.

 Adjusting and maintaining the oil level.

Bearings detailed approach:

 Know the types of bearings.

 Choosing bearings using manufacturers' catalogs.

 Cold installation, adjustment and installation of bearings.

o Spherical bearing.

o Conical bearing (stylized).

 Installation, adjustment and installation of bearings by heating.

 Know the types of bearings damage.

 Checking rolling bearings, knowing their types and

Verbal tests and works Tests and editorial work

Practical performance

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Page 16 of 64 causes, and drafting the inspection report.

 Partial arc bearings examination, knowledge of their types and causes, and drafting of the inspection report.

 Maintenance and modification of partial arc bearings, inclined pillow bearings and report drafting.

 Adjusting and maintaining the oil level.

Subject references

1. Mounting and Maintenance of Rolling Bearings, by schaffler technologies, FAG, Schaeffler Technologies GmbH & Co. KG, pages 18-143.

2. Industrial Mechanics, Albert W. Kemp, A. T. Publishers 2012, Pages 363- 380.

3. SKF Bearing Installation and Maintenance Guide, SKF USA 2007. Pages 3- 48

18 Theoretical detailed approach to lubrication:

 Learn about the lubrication and lubrication processes.

 Types of oils and greases.

 Oil and grease materials.

 Characteristics of oils and greases separately.

 General precautions to deal with oils and greases.

 Oil and Grease Selection Guide.

 Know the different methods of lubrication and lubrication.

 A comparison of oils and greases by their properties.

The practical approach to detailed lubrication and lubrication:

 Examination of oils and greases.

 Viscosity calculations for different oils.

 Methods of storing and coding oils and residues.

 Manual selection of oils and greases by manufacturers.

 Determining a preventive maintenance schedule for oil and lubrication changes according to the manufacturer's maintenance manual: an example of a lathe or any mechanical machine.

 Practically changing oils and lubricants according to the preventive maintenance calendar.

 Edit the maintenance report.

Subject references

2. SKF Bearing Installation and Maintenance Guide, SKF USA 2007. Pages 87-101

3. Mounting and Maintenance of Rolling Bearings, by schaffler technologies, FAG, Schaeffler Technologies GmbH & Co. KG, pages 79-94.

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Page 17 of 64

Theoretical detailed approach comparisons and transmission shafts

(Shafts and Couplings):

 Explanation of the functions of comparisons.

 Know the types of couplings.

 Coupling selection using manufacturers' catalogs.

 Choose “keys” nails and define their dimensions.

 Know the characteristics and dimensions of the transmission shafts.

 Check the transmission shafts.

 Explain the traditional methods for adjusting the parallel shafts of transmission.

 Knowing the effect of asymmetric transmission shafts on damaging mechanical machines.

 Explanation of the method for adjusting the transmission shafts with lasers.

The detailed, practical approach provides couplings and transmission shafts

 (Shafts and couplings):

 Know the types of couplings.

 Examining comparisons and drafting the examination report.

 Choosing “keys” nails, determining their dimensions, making “Keys Bar” and installing them.

 Examining and measuring comparisons and drafting the examination report.

 Check and measure transmission shafts and draft the inspection report.

 Adjusting the parallel transmission shafts by conventional methods and drafting the maintenance report:

o Face and Rim Method o Reverse Method

Adjust the alignment of the transmission shafts with the laser and draft the maintenance report.

Subject references

1. Pruftechnik, “Practical Guide to Shaft Alignment”, Ludeca, Pruftechnik LTD 2002, pages 6-62.

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Page 18 of 64 References

6. Industrial Mechanics, 2012, by Albert W. Kemp.

7. Industrial Mechanics and Maintenance, 3rd Edition, by Larry Chastain.

8. Industrial Maintenance, 2nd Edition 2013, by Michael E. Brumbach, Jeffrey A. Clade.

9. Industrial Maintenance, 1st Edition 2003, by Michael E. Brumbach 10. Industrial Maintenance Mechanic Trainee Guide, 3rd Edition by NCCER.

11. Mechanical Principles and Systems for Industrial Maintenance, 1st Edition by Richard R.

Knotek, Jon R. Stenerson.

12. Mounting and Maintenance of Rolling Bearings, by schaffler technologies, FAG.

13. Maintenance Engineering Handbook, 8th Edition 2014, by Keith Mobley.

14. SKF Bearing Installation and Maintenance Guide.

15. Pruftechnik, “Practical Guide to Shaft Alignment”, Ludeca.

16. Machinery Failure Analysis and Troubleshooting: Practical Machinery Management for

Process Plants 4th Edition 2012, by Heinz P. Bloch, Fred K. Geitner.

17. Mechanical Systems for Industrial Maintenance, 1st Edition 2001, by Richard R. Kibbe

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Name Maintenance of mechanical elements 2 Course

Code MAIN 252

Prerequisite 151 PRO

Credit hours 4

(Hour/ week)

Session 2

Practical 4

Training 0

This course completes the previous course (Maintenance of mechanical elements (1)) and provides the trainee with the theoretical and practical bases for maintenance of the rest of the mechanical elements common in the industry, which are leaks, chain belts, V-shaped belts, variable speed transmissions, gears, and speed reducers.

Giving the trainee the basics of maintaining the most important mechanical elements commonly used in industry.

First: cognitive goals:

The trainee should be able to:

1. Learn about the types of mechanical equipment, designs and work methods.

3. Identify equipment malfunctions and problems.

5. Carrying out maintenance of mechanical equipment.

Second: procedural objectives:

The trainee should be able to:

1. Dismantle, install, check and maintain the seals.

2. Unscrew, install and check the belts and their weight.

3. Removal, installation, inspection and maintenance of gears and transmissions.

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Page 20 of 64

Sealants 14 28

Belts 10 20

Gears and transmissions 8 16

Total 32 64

96

Safety procedures and requirements:

The trainee is keen on the safety and security procedures followed in the maintenance workshops so he puts the tools in their right place and are keen on avoiding the sharp edges of the tools and devices, as well as the cleanliness of the place, appropriate lighting and wearing protective equipment (glasses, shoes, hat, masks, etc.). The trainee must also Follow the instructions of the trainer and do not perform experiments or disassemble and install except under the supervision of the trainer.

42

Theoretical and detailed method of seals:

 Introduce and explain the basic principles of mechanical

"isolation"

 Define types of seals

 Defining its characteristics and method of selection from the manufacturers' catalogs

 Explanation of removal and installation methods and tools

 Define the types of damage and their causes

 Include it in preventive maintenance schedule A detailed, practical approach to Seals:

 Know the types of seals and distinguish between them

 Selection of seals using manufacturers' catalogs

 Seal, Examine, and Install: Seals

 Inspection, removal, manufacture and installation of gaskets: gaskets

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Page 21 of 64

30

Theoretical and detailed approach to belts and chains (Belts and Chains)

 Learn the ways of conveying power with belts

 Belt components and minerals

 Belt types and their technical characteristics

 How to choose belt types from manufacturers' catalogs

 Types of belt damage and their causes

 Belt tension adjustment and tools

 Traditional methods for adjusting the parallel ball belt

 Method of adjusting the belt rollers with lasers

 Chained power transmission methods

 Chains components

 Types of chains and their technical characteristics

 How to Choose Chain Types from Manufacturers' Catalogs

 Types of chains damage and their causes

 Methods of adjusting and chain tensioners and adjusting the parallelism of rollers

The practical, detailed approach provides belts and chains (Belts and Chains)

 Learn about the types of belts and their characteristics

 Types of belt damage and their causes

 Belt tension adjustment

 Adjustment of the belt rollers parallel with traditional methods

 Parallel alignment of belt pulleys with lasers

 Types of chains and their technical characteristics

 Types of chains damage and their causes

 Chain tension adjustment and Roller Parallel adjustment

Subject references

1. Belt Design, Gates Rubber Company 2001, pages 2-270.

3. Mounting and Maintenance of Rolling Bearings, by schaffler technologies, FAG, Schaeffler Technologies GmbH & Co. KG, pages 102-139

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Page 22 of 64

Theoretical detailed approach to gears and transmissions

(Gears and transmission):

 The principle of transmitting power, torque, speed and the relationship between them

 Learn about power transmission methods with gears

 Technical gear characteristics

 Types of gears

 Types of gear damage and their causes

 Speed boxes and the coefficient of reducing or increasing torque and speed

 Check and measure gears and tools

 Mechanical transmissions

 Hydraulic transmissions

 Air transmitters

A detailed, practical approach to gears and transmissions

(Gears and transmission):

 Learn about mechanical transmissions

 Types of toothed gears

 Dynamics of gears and breakdown patterns

 Common features

 Troubleshoot problems

 Corrosion and overload

 Types of mechanical transmissions

 Knowing the diameter of the step circle and the central dimension:

- Circular and diagonal step and its measurements - Learn about transport systems (vectors)

 Pneumatic transmission systems

 Mechanical transmission systems

 Screw conveyor systems

 Operating and configuration systems:

o Exercises and exercises

o Check gears and transmissions

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Page 23 of 64

o Install gears and transmissions o Install gears and transmissions o Preventive maintenance of gears and

transmissions

o Periodic maintenance o Corrective maintenance Subject

references

References

18. Industrial Mechanics, by Albert W. Kemp, 2012.

19. Industrial Mechanics and Maintenance, 3rd Edition, by Larry Chastain.

20. Industrial Maintenance, 2nd Edition 2013, by Michael E. Brumbach, Jeffrey A. Clade.

21. Industrial Maintenance, 1st Edition 2003, by Michael E. Brumbach 22. Industrial Maintenance Mechanic Trainee Guide, 3rd Edition by NCCER.

23. Mechanical Principles and Systems for Industrial Maintenance, 1st Edition by Richard R.

Knotek, Jon R. Stenerson.

24. Mounting and Maintenance of Rolling Bearings, by schaffler technologies, FAG.

25. Maintenance Engineering Handbook, 8th Edition 2014, by Keith Mobley.

26. SKF Bearing Installation and Maintenance Guide.

27. Pruftechnik, “Practical Guide to Shaft Alignment”, Ludeca.

28. Machinery Failure Analysis and Troubleshooting: Practical Machinery Management for Process Plants 4th Edition 2012, by Heinz P. Bloch, Fred K. Geitner.

29. Mechanical Systems for Industrial Maintenance, 1st Edition 2001, by Richard R. Kibbe

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Name Workshop and welding technology Course

Code MAIN 171

Credit hours 4

(Hour/ week)

Session 2

Practical 4

Training 0

This course provides the trainee with the theoretical and practical foundations in operating production and welding workshop machines and the necessary technical skills in the field of mechanical

machinery maintenance.

It aims to provide the trainee with the foundations of operating production and welding workshop machines commonly used in industry.

1. Choose the appropriate operating method.

2. Knowing the effects on the economic aspects of employment.

3. Determine the appropriate operating conditions for different cutting operations.

4. Operation and management of machines in the correct and proper way.

5. Supplying and operating the necessary equipment and machines for carrying out welding operations.

6. Determination of current strength, voltage difference, welding electrodes, protective powders and inert gases.

Second: procedural goals:

1. Determine the appropriate operating conditions for different cutting operations.

2. Operation and management of machines in the correct and proper way.

3. Planning the product, studying time and determining the required operating stages.

4. Perform arc welding and oxy-acetylene welding.

5. Welding quality inspection and treatment of welding defects.

6. Ensure that the production lines are fed with the raw materials to be manufactured, check these materials before starting the production process and provide the tools necessary for safety and to carry out the required work.

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Page 25 of 64

Safety in the workshop 2 2

Basics of cutting 4 4 4 2

Cutting (turning, milling) 10 28

Introduction to welding technology 2 4

Basics of arc welding 6 12

Oxy-acetylene welding 6 12

Welding defects and methods of examination 2 4

Total 32 64

96

1. The trainee is keen on the safety and security procedures followed in the production and welding workshops.

3. The trainee is keen to avoid sharp edges of tools and devices.

4. The trainee is keen on cleaning the place, and appropriate lighting.

5. The trainee wears protective equipment (glasses, shoes, hat, masks, etc.).

4

Safety in the workshop:

 Personal safety

 Safety of individuals

 Safety of equipment

 Structural Safety

 Environmental safety Security and safety procedures

Subject references

1. Occupational Safety and Health for Technologists, Engineers, and Managers, 7th Edition by David L. Goetsch

44

Cutting operations (turning, milling):

 Turning

Cutting tools Cutting conditions (feeding - cutting depth - cutting speed - rotating speed).

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Page 26 of 64

 Milling

Cutting tools Cutting conditions (feeding - cutting depth - cutting speed - rotating speed).

o Exercises and exercises o Turning:

 Checking, equipping and operating the lathe

 Select and install lathe pens

 Fixing the work piece on the lathe

 Executing longitudinal turning, frontal turning and internal turning

 Cut internal and external screws o Milling:

 Selecting, equipping and operating the milling machine

 Selection and fixing of milling clips

 Install the work pieces

o Produce flat surfaces of specific dimensions Subject

references

1. Machining Fundamentals, 9th Edition 2013, by John R. Walker, Bob Dixon.

Pages 201-274 and 285-352.

6

Welding Technology Introduction:

 Definition of welding and its types

 Welding connections and welding symbols

 Gas and electric welding safety rules:

o Exercises and exercises o Types of welding

o Welding connections and welding symbols

Subject references

1. Welding: Principles and Applications, 7th Edition 2012, by Larry Jeffus.

Pages 1-47 and 542-560.

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Page 27 of 64

18

Electric arc welding basics:

 Its idea

 Its types

 Its advantages

 Electric and polar current o Exercises and exercises o Electric arc welding exercises'

Safety controls applied o Link preparation

o Welding implementation

Subject references

1. Welding: Principles and Applications, 7th Edition 2011, by Larry Jeffus.Pages 49-121.

18

Oxy-acetylene welding:

 Gases used

 hardware

 Welding execution controls o Exercises and exercises o Oxy-acetylene welding drills o Safety controls applied o Link preparation

o Welding implementation

Subject

references 1. Welding Skills, 5th Edition 2014, by B. J. Moniz 6 Welding defects and methods of examination:

 Types of defects and their causes.

 Controls to avoid defects when welding.

 Methods for detecting welding defects:

o Exercises and exercises o Welding quality evaluation

Subject references

1. Welding: Principles and Applications, 7th Edition 2011, by Larry Jeffus. Pages 602-628.

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Page 28 of 64 References

 Machining Fundamentals, 9th Edition 2013, by John R. Walker, Bob Dixon.

 Precision Machining Technology, 2nd Edition, by Peter J. Hoffman, Eric S. Hopewell, Brian Janes.

 Manufacturing Processes for Engineering Materials, 5th Edition, by Serope Kalpakjian, Steven Schmid.

 Introduction to Manufacturing Processes, 1st Edition 2011, by Mikell P. Groover.

 Welding: Principles and Applications, 7th Edition 2011, by Larry Jeffus.

 Welding Skills, 5th Edition 2014, by B. J. Moniz.

 Welding, 2nd Edition 2011, by Don Geary, Rex Miller.

 Welding Skills Workbook, 5th Edition, By: Jonathan F. Gosse

 Welder's Handbook A Guide to Plasma Cutting, Oxyacetylene, ARC, MIG and TIG Welding Revised Edition, by Richard Finch

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Name Maintenance of mechanical systems Course

Code MAIN 253

Credit hours 4

(Hour/ week)

Session 2

Practical 4

Training 0

This course provides the trainee with the theoretical and practical foundations for the maintenance of some common mechanical systems in the industry, such as cranes of all types, balance, tubes and valves of all kinds, methods of operation and maintenance. It also displays types of boilers, heat exchangers, Vapor traps and their maintenance methods

Giving the trainee the foundations of maintaining mechanical equipment commonly used in industry.

1. It lists the types of mechanical equipment and their designs and explains their working methods.

3. Diagnose equipment faults and problems.

5. Carrying out maintenance of mechanical equipment Second: procedural objectives:

1. Examination, dismantling, installation and maintenance of overhead cranes at their facilities.

2. Lifting loads and equipment using the proper Cranes properly and correctly.

3. Dismantle, install and check tubes.

4. Unscrew, install, check and maintain valves of all kinds.

5. Removal, installation, inspection and maintenance of all types of Vapor traps.

6. Examination and maintenance of heat exchangers of all kinds.

7. Boiler inspection and maintenance.

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Page 30 of 64

Overhead Cranes and their types 4 8

The tubes 6 12

Valves and their types 8 16

Vapor traps and their types 2 4

Heat exchangers and their types 6 12

Vapor boilers and their types 6 12

Total 32 64

96

1. The trainee is keen on the safety and security procedures used in the workshops and laboratories.

3. The trainee is keen to avoid sharp edges of tools and devices.

4. The trainee is keen on cleaning the place, and appropriate lighting.

5. The trainee wears protective equipment (glasses, shoes, hat, masks, etc.).

6. Refer to appropriate safety instructions for each Subject.

12

1- Overhead Cranes

 Learn about the types of overhead cranes.

 Parts of overhead cranes.

 Installing the upper cranes.

 Loading on overhead cranes:

o Exercises and exercises o Installing cranes

o Installing cranes

 Check the cranes.

 Preventive and corrective maintenance of cranes.

Subject references

Rigging, Hoisting, and Signaling Practices, 2010, By In Partnership with NJATC. (All the book is reference for this Subject)

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Page 31 of 64

18

Piping:

 an introduction

 Identify the types, advantages and disadvantages of pipes

 Identification of pipe materials

 Water problems in pipes and methods of treatment

 Pipe seals

 Pipe fitting and welding methods

 thermal insulation

 - Pipe accessories

o Exercises and exercises o Pipe installation

o Install the pipes o Check the tubes

o Preventive and corrective maintenance of pipes

Subject references

1. Piping Systems Manual, by Brian Silowash, 2010. All the book is a reference for this Subject)

24 Valves:

 Types of valves and their uses

 Advantages and disadvantages of each type

 Methods of connection and fitting of valves

 Valve components

o Exercises and exercises o Valves installation o Install valves o Check valves

o Preventive and corrective maintenance of valves

Subject references

1. Piping Systems Manual, 2009, by Brian Silowash. Pages 183-220.

2. Valve Handbook 3rd Edition, 3rd Edition, by Philip Skousen.

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Page 32 of 64

6

Vapor traps:

 Types of Vapor traps

 Vapor traps uses

 Advantages and disadvantages

 Vapor components

o Exercises and exercises o Installing Vapor traps o Installing Vapor traps o Check the Vapor traps

o Preventive and corrective maintenance of Vapor traps

Subject references

1. Steam trap applications introduction to steam traps, by Watson McDoniel.

18 Heat Exchangers:

 Types of heat exchangers

 Common advantages and disadvantages of each type

 Heat exchanger components

 Uses of heat exchangers

 Heat exchange and heat exchanger efficiency o Exercises and exercises

o Installing heat exchangers o Installing heat exchangers o Check the heat exchangers

o Preventive and corrective periodic maintenance of heat exchangers

Subject references

1. Heat Exchangers: Selection, Rating, and Thermal Design, 3rd Edition 2012, by Sadik Kakaç, Hongtan Liu, Anchasa Pramuanjaroenkij.

18 Boilers:

- Types of steam boilers and the use of each type - Main parts and purpose of the boiler

- The way the boilers work

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Page 33 of 64

- Advantages and disadvantages of each type - Boiler malfunction diagnosis

- Operating and testing the performance of steam boilers

- Preventive and repair maintenance of steam boilers Subject

references

1. Safe Boiler Operation Fundamentals: Special Engineer's Guide for the State of Minnesota by In Partnership with TFM.

References

 Rigging, Hoisting, and Signaling Practices, 2010, By In Partnership with NJATC.

 Rigging Equipment: Maintenance and Safety Inspection Manual, 1st Edition 2010, by Joseph MacDonald.

 Handbook of Rigging: For Construction and Industrial Operations, 5th Edition, by Joseph MacDonald, W. Rossnagel, Lindley Higgins.

 The Piping Guide: For the Design and Drafting of Industrial Piping Systems Hardcover, 2009, by Dennis J Whistance, David R Sherwood.

 Piping Systems Manual, 2009, by Brian Silowash.

 Piping Handbook, 7th Edition, by Mohinder Nayyar.

 Pipe Drafting and Design, 3rd Edition 2011, by Roy A. Parisher, Robert A. Rhea.

 Valve Handbook 3rd Edition, 3rd Edition, by Philip Skousen.

 Facility Piping Systems Handbook: For Industrial, Commercial, and Healthcare Facilities, 3rd Edition, by Michael Frankel.

 Steam trap applications introduction to steam traps, by Watson McDoniel.

 Maintenance Engineering Handbook, 8th Edition, by Keith Mobley.

 Heat Exchangers: Selection, Rating, and Thermal Design, 3rd Edition 2012, by Sadik Kakaç, Hongtan Liu, Anchasa Pramuanjaroenkij.

 Heat Exchanger Design Handbook (Mechanical Engineering), 2nd Edition 2013, by Kuppan Thulukkanam.

 Heat and Mass Transfer: Fundamentals and Applications, 5th Edition 2014, by Yunus Cengel (Author), Afshin Ghajar.

 Heat Transfer (McGraw-Hill Series in Mechanical Engineering), 10th Edition 2009, by Jack Holman

 Heat Exchanger Equipment Field Manual: Common Operating Problems and Practical Solutions, 1st Edition 2012, by Maurice Stewart, Oran T. Lewis

 High Pressure Boilers, 5th Edition 2012, By Frederick M. Steingress, Harold J. Frost, Daryl R.

Walker.

 Low Pressure Boilers, 4th edition 2012, by Frederick M. Steingress, Daryl R. Walker.

 Safe Boiler Operation Fundamentals: Special Engineer's Guide for the State of Minnesota by In Partnership with TFM.

 Boiler Operator's Guide, 4th Edition, by Anthony Kohan.

 Industrial Mechanics, 4th Edition, By Albert W. Kemp.

 Industrial Maintenance, 3rd Edition, By: Denis Green, Jonathan F. Gosse.

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Name Electro-mechanical machinery Course

Code MAIN 221

Prerequisite 101 PHY

Credit hours 4

(Hour/ week)

Session 3

Practical 2

Training 0

This course introduces the trainee the theoretical and practical foundations of electrical and electronic technology through the definition of the basic laws in electricity and electronics and the definition of basic electrical and electronic elements and their installation in different departments and their practical applications (electric motors and control boxes).

Giving the trainee the foundations of electrical and electronic technology to enable him to identify the basic electrical and electronic elements and install them in various departments in industrial machines and equipment.

1. Define basic electrical quantities such as current strength, voltage difference, resistance and electrical power.

2. Defining Ohm's Law and its applications.

3. Use of conductive materials, resistance materials and insulating materials.

4. Design and connect electrical circuits.

5. It explains the types of semiconductor materials, diode composition and applications.

6. It explains the composition and properties of the transistor.

7. Design and connect electronic circuits.

Second: procedural objectives:

1. Calculation of the difference of current voltage, current intensity and amount of resistance.

2. Design and connect electrical circuits.

3. Checking and repairing electrical circuits.

4. Design and connect electronic circuits.