MECHANICAL SECTION

Training Course Syllabus

 

1.   Basic Maintenance for Patroller (3 days)

• Autonomous Maintenance
• Basic Condition Monitoring
• Daily Checking
• Cleaning
• Lubrication
• Introduction
• Objective of inspections
• Examples of damages
• Reasons for defects
• Inspection methods / tests
• Setting up Inspection Schedules
  • Patrol Inspections of Operation Condition
  • Steps of quality assurance
  • Inspection program
  • Monitoring condition
  • Minor trouble shooting
  • Equipment Related Safety

2.   Inspections for Cement Plant Equipment (3 days)

 

3.   Condition Monitoring (3 days)

• Introduction
• Objectives
• Definition of Condition Monitoring
• Condition Monitoring Techniques
• Visual Observations, Listening, Touching
• Machinery vibration analysis
  • Measuring points
  • Vibration severity
  • Analysis frequency
  • Advantages / limitations
  • Bearing vibration analysis
    • Shock Pulse Method
    • Limitations/advantages
  • Motor Current Signature Analysis
    • Analysis frequency
    • Advantages/limitations
  • Oil Analysis
    • Oil sampling procedure
    • Analysis frequency
    • Advantages/limitations
    • Contamination Analysis
    • Wear Particle Analysis
  • Performance Trending
    • Analysis frequency
    • Advantages/limitations

 

4.   Hydraulics and Pneumatics (3 days)

• Hydraulics theory
• Pneumatics theory
• Working System
• Troubleshooting
• Maintenance
  • Principles of
  • Industrial hydraulic systems
  • Roller mill hydraulics
  • Cooler drives
  • Kiln hydraulics
  • Stacker/reclaimer hydraulics
  • 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 
• 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

6.   Transport Equipment Maintenance (3 days)

 

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
• Condition Monitoring
• Vibration
• Precision tools
• Alignment
• Bearings
• Temperature
• Pressure Draft
• Ultrasonic
• Unbalance Condition
• Safety Considerations
• Condition Monitoring
• Reduction Gear (gear boxes)
• Inspection
• Trouble Shooting
• Repairs and Maintenance
• Equipment Related Safety
• Design of Equipments
• Troubleshooting
• Maintenance
• Repair
• Assembly
• Equipment Related Safety

15.       Mechanical Analysis (3 days)

16.       Mechanical Drive Systems (3 days)

17.       Mechanical Maintenance Practices (3 days)

 

18.       Mechanical Design and Analysis (3 days)

 

• Belt Conveyor
  • Function and Operation
  • Design
  • Calculation
  • Coupling
    • Function and Operation
    • Design
    • Calculation
    • Bearing
      • Function and Operation
      • Design
      • Calculation
      • Pump
        • Function and Operation
        • Design
        • Calculation
        •  
        • Fan
          • Function and Operation
          • Design
          • Calculation
          • Troubleshooting
          • Bucket Elevator
            • Function and Operation
            • Design
            • Calculation of capacity 
            • Bag Filter
              • Function and Operation
              • Design
              • Calculation
              • Alignment of As
                • As alignment
                • Method of reverse dial and procedure
                • Method of Face and Rim
                • Mechanical Vibration and Measurement
                  • Vibration parameter
                  • Calculation of parameter
                  • Vibration sensor
                  • 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