Visitors :4060 Org
Hits : 14618 hits
Month : 172 UsersSylabus Mechanical Section
1. Basic Maintenance for Patroller (3 days)
§ Autonomous Maintenance
§ Basic Condition Monitoring
§ Daily Checking
§ Cleaning
§ Lubrication
2. Inspections for Cement Plant Equipment (3 days)
§ Introduction
§ Objective of inspections
§ Examples of damages
§ Reasons for defects
§ Inspection methods / tests
§ Setting up Inspection Schedules
o Patrol Inspections of Operation Condition
o Steps of quality assurance
o Inspection program
o Monitoring condition
o Minor trouble shooting
§ Equipment Related Safety
3. Condition Monitoring (3 days)
§ Introduction
§ Objectives
§ Definition of Condition Monitoring
§ Condition Monitoring Techniques
§ Visual Observations, Listening, Touching
§ Machinery vibration analysis
o Measuring points
o Vibration severity
o Analysis frequency
o Advantages / limitations
§ Bearing vibration analysis
o Shock Pulse Method
o Limitations/advantages
§ Motor Current Signature Analysis
o Analysis frequency
o Advantages/limitations
§ Oil Analysis
o Oil sampling procedure
o Analysis frequency
o Advantages/limitations
o Contamination Analysis
o Wear Particle Analysis
§ Performance Trending
o Analysis frequency
o Advantages/limitations
4. Hydraulics and Pneumatics (3 days)
§ Hydraulics theory
§ Pneumatics theory
§ Working System
§ Troubleshooting
§ Maintenance
§ Principles of
o Industrial hydraulic systems
o Roller mill hydraulics
o Cooler drives
o Kiln hydraulics
o Stacker/reclaimer hydraulics
o High pressure lubrication systems
§ Reading Hydraulic Diagrams
§ Components of Hydraulic Systems - Design and Function
§ Elements of Control Systems
§ Hydraulic Fluids and Fluid Conditioning
§ Maintenance and Trouble-Shooting
§ Review of Specific Hydraulic Systems
§ Repair
§ Equipment Related Safety
5. Maintenance Procedures for Lubrication System (3 days)
§ Lubrication Theory
§ Choice of Lubricant
§ Control and Safety Feature
§ Differential Pressure Across Filter
§ Preventive Maintenance
§ Refilling of Oil Tank
§ Lubrication Unit
§ Oil Tank Lubricating Oil
§ Oil Filter
§ Thermal Sensors
§ Flow Indicators
§ Level Switch
§ Analysis
§ Condition monitoring
§ Planning
§ Execution
§ Viscosity
§ Safety Considerations
6. Transport Equipment Maintenance (3 days)
§ Stacking Reclaiming : Function, Operation, Maintenance
§ Belt Conveyor : Function, Operation, Maintenance
§ Bucket Elevator : Function, Operation, Maintenance
§ Dosimat Feeder : Function, Operation, Maintenance
§ Drag Chain : Function, Operation, Maintenance
§ Fluxo Slide : Function, Operation, Maintenance
§ Belt Conveyor : Function, Operation, Maintenance
§ Screw Conveyor : Function, Operation, Maintenance
7. The Maintenance Management (3 days)
§ Maintenance Requirements
§ Critical Asset
§ Works Order System
§ Maintenance Master Schedule
§ Daily / Weekly Plan
§ Maintenance KPI's
§ Daily Maintenance Report
§ Maintenance Cost Structure
§ Production Plan
§ Spares Policy & Management
§ Standards & Specifications
§ Asset History System
§ Weekly Maintenance Report
§ Maintenance Cost Report
§ Resource Skills Matrix
§ Budget
8. Kiln System Maintenance (3 days)
§ Maintenance Procedures for Preheater System
§ Maintenance Procedures for Kiln Shell and Planetary Cooler
§ Maintenance Procedures for Kiln Supports
§ Maintenance Procedures for Kiln Drive
§ Alignment and Mechanical Balance of Kiln
§ Maintenance Procedures for Grate Coolers
§ Proper kiln maintenance techniques
§ Alignment and ovality measurements to prevent break-downs
§ Inspection and maintenance of the clinker cooler
9. Ball Mill Maintenance (3 days)
§ Importance of Mill Availability
§ Mill System Components
§ Maintenance Procedures for Mill Shells
§ Maintenance Procedures for Mill Supports
§ Maintenance Procedures for Mill Drive
§ Maintenance Procedures for Mill Seals
§ Maintenance Procedures for Mill Lubrication System
§ Mill Alignment
§ Proper mill maintenance procedures
§ Preventing breakdowns
10. Gearbox Maintenance (3 days)
§ Description and Operational Principles of Gearboxes
§ Measurement of Vibrations
§ Maintenance Procedures: Inspection of Teeth
§ Maintenance Procedures: Inspection of Roller Bearings
§ Maintenance Procedures: Lubrication Systems
§ Safety Systems
§ Installation and Commissioning of Gearboxes
§ Introduction to Vibration Analysis
§ Introduction to Troubleshooting
§ Safety Regulations
§ The operational aspects of gearboxes,
§ Proper gear maintenance procedures
§ Prevent breakdown
11. Total Productive Maintenance (3 days)
§ Definition
§ Equipment Management
§ Focused Improvement
§ Autonomous Maintenance
§ Planned Maintenance
§ Early Management
§ Quality Maintenance
§ Measure Effectively of TPM
§ Evaluate Effectively of TPM
12. Vertical Mill Maintenance (3 days)
§ Design of Process, Machinery and Basic Principles of Operation
§ Mill Components
§ Hydraulic Tensioning System
§ Roller Lubrication System
§ Drive System and Lubrication
§ Separator
§ Mill Feed System
§ Maintenance Aspects
§ Proper mill maintenance procedures
§ Preventing breakdowns
13. Coal Mill Maintenance (3 days)
§ Importance of Mill Availability
§ Design of Process, Machinery and Basic Principles of Operation
§ Design Considerations
§ Mill Components
§ Drive System Maintenance
§ Hydraulic Systems Maintenance
§ Lubrication Systems Maintenance
§ Alignment and Inspection
§ Other Maintenance Measures
§ Operation of the Vertical Mill
§ Proper mill maintenance procedures
§ Preventing breakdowns
14. Reliability Centered Maintenance (3 days)
§ Brief history of Reliability-Centered Maintenance (RCM)
§ Definition and principles
§ RCM implementation methods
§ Predictive maintenance
§ Plant registration
§ Function and failure
§ Preventive works
§ Default actions
15. Mechanical Analysis (3 days)
§ Condition Monitoring
§ Vibration
§ Precision tools
§ Alignment
§ Bearings
§ Temperature
§ Pressure Draft
§ Ultrasonic
§ Unbalance Condition
§ Safety Considerations
16. Mechanical Drive Systems (3 days)
§ Condition Monitoring
§ Reduction Gear (gear boxes)
§ Inspection
§ Trouble Shooting
§ Repairs and Maintenance
17. Mechanical Maintenance Practices (3 days)
§ Design of Equipments
§ Troubleshooting
§ Maintenance
§ Repair
§ Assembly
§ Equipment Related Safety
18. Mechanical Design and Analysis (3 days)
§ Belt Conveyor
o Function and Operation
o Design
o Calculation
§ Coupling
o Function and Operation
o Design
o Calculation
§ Bearing
o Function and Operation
o Design
o Calculation
§ Pump
o Function and Operation
o Design
o Calculation
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§ Fan
o Function and Operation
o Design
o Calculation
o Troubleshooting
§ Bucket Elevator
o Function and Operation
o Design
o Calculation of capacity
§ Bag Filter
o Function and Operation
o Design
o Calculation
§ Alignment of As
o As alignment
o Method of reverse dial and procedure
o Method of Face and Rim
§ Mechanical Vibration and Measurement
o Vibration parameter
o Calculation of parameter
o Vibration sensor
o Measurement
19. Auxiliary Equipments (3 days)
§ Water supply equipment : function, operation, maintenance, troubleshooting
§ Compressor : function, operation, maintenance, troubleshooting
§ Fans : function, operation, maintenance, troubleshooting
§ Heat exchanger : function, operation, maintenance, troubleshooting
§ Pump : function, operation, maintenance, troubleshooting
§ Blower : function, operation, maintenance, troubleshooting
§ Dryer : function, operation, maintenance, troubleshooting