50-464-717Precision Alignment, Pumps & Pumping Systems for Maintenance Tech Apprentices
Course Information
Description
Course learning outcomes include competencies related to pumps, compressors, couplings, and precision alignment. Course compares different coupling types and examines common misalignment problems. Apprentices will develop skills related to inspecting, troubleshooting, and preparing couplings for removal and installation, and also aligning and lubricating couplings. Laser alignment techniques will be introduced. Apprentices will also examine pumps, pump types, operating specifications, and their applications. Pump components such as packings, seals, gaskets, materials of construction, and related instrumentation are included in the course. Course competencies focus on inspection, testing, service, repair and maintenance of pumps and pumping systems.
Total Credits
2
Course Competencies
  1. Examine pipe sizes, materials and schedules
    Assessment Strategies
    Piping Worksheet
    Criteria
    apprentice correctly identifies pipe type and size
    apprentice correctly identifies pipe material
    apprentice correctly identifies type of thread
    apprentice matches pipe types to a given specific application

  2. Examine types of pipe fittings
    Assessment Strategies
    Piping Worksheet
    Criteria
    apprentice correctly identifies a specific fitting
    apprentice correctly identifies a specific thread
    apprentice can explain the use for a given fitting

  3. Examine different types of tubing and their related components
    Assessment Strategies
    Piping Worksheet
    Criteria
    apprentice correctly identifes tubing size and type
    apprentice explains how tubing is sized
    apprentice correctly identifes tubing material
    apprentice correctly identifes tubing connectors
    apprentice correctly identifes tubing valves

  4. Install tubing with fittings
    Assessment Strategies
    Piping Worksheet
    Skill Demonstration
    Criteria
    apprentice cuts tubing to correct length
    apprentice deburrs cut as required
    apprentice makes flare to correct angle as required
    apprentice selects the correct tool for cutting/deburring/flaring/bending etc.
    flare is not cracked and does not stress metal
    by selecting tubing and related components for a specific application
    by cutting tubing
    by flaring tubing
    by installing a fitting

  5. Examine different types of valves and their related components
    Assessment Strategies
    Piping Worksheet
    Criteria
    apprentice uses valve nomenclature
    apprentice explains how a given valve works and identifies it by its components
    apprentice properly locks out or describes how to properly lockout and bleed a valve
    apprentice identifies why a valve failed and can give examples
    apprentice selects a correct valve for a given application
    apprentice correctly replaces a valve or describe its replacement
    apprentice disassembles and repairs a valve

  6. Layout a piping system
    Assessment Strategies
    Piping Worksheet
    Criteria
    apprentice designs a piping system for a given application
    apprentice draws a simple schematic
    apprentice selects the correct pipe for an application
    apprentice selects the proper joining procedure i.e. threading, compression, weld, etc.
    apprentice explains safety procedures for the system
    apprentice creates a simple installation schematic
    apprentice selects valves and valve material according to the application
    layout includes routing and pipe support locations

  7. Install a piping system
    Assessment Strategies
    Piping Worksheet
    Criteria
    apprentice follows safety procedures for piping installation
    apprentice installs the correct fittings and elbows
    piping system operates properly as per the layout
    apprentice plans a piping system installation mock up

  8. Maintain piping systems
    Assessment Strategies
    Piping Worksheet
    Criteria
    apprentice follows established maintenance precautions
    apprentice follows established maintenance procedures
    apprentice completes a scheduled maintenance task work plan

  9. Examine types of packing, seals, and gaskets
    Assessment Strategies
    Seals & Gaskets Worksheet
    Criteria
    apprentice can correctly identify types of packings
    apprentice can correctly identify types of seals
    apprentice can correctly identify types of gaskets

  10. Examine packing, seal, and gasket materials and applications
    Assessment Strategies
    Seals & Gaskets Worksheet
    Criteria
    apprentice identifies packing material
    apprentice can explain packing application and construction
    apprentice identifies seal material
    apprentice can explain seal application and construction
    apprentice identifies gasket material
    apprentice can explain gasket application and construction

  11. Layout and cut gaskets
    Assessment Strategies
    Seals & Gaskets Worksheet
    Skill Demonstration
    Criteria
    apprentice selects correct gasket material
    apprentice uses the correct tool(s)
    apprentice follows correct layout procedure
    the gasket conforms to specification requirements
    the gasket is not damaged

  12. Inspect packings, seals, and gaskets
    Assessment Strategies
    Seals & Gaskets Worksheet
    Criteria
    apprentice selects the correct packing for a given application
    apprentice selects the correct seal for a given application
    apprentice selects the correct gasket for a given application
    apprentice notes defects during inspection
    apprentice can describe defect types

  13. Remove packings, seals, and gaskets
    Assessment Strategies
    Seals & Gaskets Worksheet
    Skill Demonstration
    Criteria
    apprentice does not damage or score the part or machine during removal
    apprentice follows all lockout/tagout and other applicable safety procedures
    apprentice attempts to determine cause of failure as applicable
    apprentice cleans surfaces during removal to allow for inspection for damage
    apprentice selects and uses the correct removal tools

  14. Install packings, seals, and gaskets
    Assessment Strategies
    Seals & Gaskets Worksheet
    Skill Demonstration
    Criteria
    apprentice ensures cleanliness during installation and assembly
    apprentice does not damage part or machine during installation
    apprentice does not damage the seal or gasket during installation
    apprentice follows all lockout/tagout and other applicable safety procedures
    apprentice follows all Material Safety Data Sheets (MSDS) recomendations as applicable
    apprentice selects and uses the correct installation tools
    apprentice refers to the applicable technical specifications for installation
    apprentice can determine what constitutes a properly performing packing, seal, or gasket
    apprentice selects the correct sealant as appropriate to the application
    apprentice selects the correct lubricant as appropriate to the application
    the packing, seal, or gasket is performing their function according to applicable technical specifications

  15. Be aware of costs, and the business motive for sustainable manufacturing improvements
    Assessment Strategies
    Written summary of the business motives behind waste reductions and cost savings from green programs and sustainable manufacturing improvements
    Criteria
    apprentice correctly identifies the costs associated with running equipment
    apprentice estimates air losses and costs associated with air leaks
    apprentice identifies the costs of misalignment
    apprentice estimates the costs associated with balanced and unbalanced equipment
    apprentice identifies plant and facility energy and resource wastes
    apprentice calculates the costs of downtime and runtime ratios/metrics
    apprentice identifies best practices
    apprentice applies world class costs and benchmarking accurately
    apprentice summarizes the business motives behind green programs and sustainable manufacturing efforts
    written summary is grammatically correct, error free, and adheres to the guidelines provided by the instructor
    written summary identifies the key points
    written summary includes only relevant and necessary details

  16. Analyze energy efficiency initiatives for industrial plants, equipment and facilities
    Assessment Strategies
    Oral, Written or Graphic Assessment
    Case Study
    Scenario Response
    Criteria
    apprentice describes energy efficient equipment options correctly
    apprentice identifies resource requirements accurately
    apprentice compares energy efficient options and alternatives
    apprentice summarizes energy efficiency technical information clearly and concisely
    written summary is grammatically correct, error free, and adheres to the guidelines provided by the instructor
    written summary identifies the key points
    written summary includes only relevant and necessary details

  17. Be aware of new materials and options for work processes
    Assessment Strategies
    Internet research related to new energy efficient materials and options for equipment and operations
    Oral summary of your key research findings during class discussion
    Class participation
    Criteria
    apprentice identifies online resources efficiently
    apprentice accurately summarizes technical information related to new materials
    apprentice provides relevant examples of applications of new materials for plants and facilities
    apprentice encourages class participation and facilitate questions and answers
    apprentice enters into class discussions
    apprentice offers questions or comments during class presentations
    apprentice actively listens during class

  18. Relate predictive and preventative maintenance testing procedures to green and sustainable manufacturing principles
    Assessment Strategies
    Comparison Paper, Oral Presentation or Graphical Assessment
    Criteria
    by comparing predictive and preventative maintenance tests including laser alignment, vibration analysis, oil analysis, ultrasonic testing, and thermal imaging
    by relating predictive and preventative maintenance tests to reducing downtimes, improving equipment performance, and reducing costs
    by summarizing how precision laser alignment of rotating machinery contributes to energy efficient operations and sustainable manufacturing
    by submitting completed work to the instructor for review and feedback
    apprentice explains the business motive for predictive maintenance
    apprentice describes the business motive for preventative maintenance
    apprentice compares and contrasts predictive and preventative maintenance testing
    apprentice applies predictive and preventative maintenance to cost reductions, energy efficiency and sustainable manufacturing principles
    apprentice relates testing procedures used in vibration analysis to predictive and preventative maintenance
    apprentice relates testing procedures involved in oil analysis to predictive and preventative maintenance
    apprentice relates testing procedures involved in ultrasonic testing to predictive and preventative maintenance
    apprentice relates testing procedures involved in thermal imaging to predictive and preventative maintenance
    apprentice relates testing procedures involved in precision laser alignment to predictive and preventative maintenance
    apprentice correlates precision laser alignment to reduced energy consumption and more efficient operations

  19. Perform precision laser alignment on rotating machines and equipment
    Assessment Strategies
    Skill Demonstration
    Criteria
    apprentice assesses potential hazards before starting testing and takes appropriate corrective action
    apprentice follows lockout and tagout safety procedures properly
    apprentice selects suitable laser alignment equipment
    apprentice inspects, tests, and zeros out laser equipment correctly
    apprentice installs and handles laser alignment equipment properly
    apprentice adheres to safety requirements and uses proper PPE while testing
    apprentice tests for vertical and horizontal alignment and all planes
    apprentice interprets test results accurately
    apprentice records as-found and as-left test results properly
    apprentice adjusts motors, shafts, and related equipment and components based on laser alignment test results
    apprentice re-tests precision alignment following equipment adjustments to verify results
    apprentice applies precision laser alignment to pumps/motors, longer shafts, and right angle alignments
    apprentice uses test results to fix soft foot problems
    apprentice adheres to industry accepted standard operating procedures for precision laser alignment

  20. Be aware of bearing maintenance procedures that contribute to reduced costs
    Assessment Strategies
    Internet research related to bearing maintenance
    Oral sharing a summary of your key research findings during class discussion
    Class participation
    List of websites you reviewed submitted to your instructor for review and feedback
    Criteria
    apprentice identifies online resources efficiently
    apprentice accurately summarizes technical information related to bearing maintenance, replacement, and service
    apprentice provides relevant examples of applications of bearing maintenance for a variety of industrial applications
    apprentice compares methods to prevent bearing contamination and seal failure
    apprentice encourages class participation and facilities questions and answers
    apprentice enters into class discussions
    apprentice offers questions or comments during class presentations
    apprentice actively listens during class