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Detailed Course Catalog IPIMS Background Learning IPIMS Action Learning Petroleum Online Business Essentials Operations & Maintenance
IPIMS
Background Learning Course Catalog
Duration: Min: 2 hours 0 minutes Max: 2 hours 40 minutes Subtopics: Petroleum Exploration Overview Seismic Met hods Fundamentals of Explorat ion Geophysics: References and Addit ional Information Topic 36 of 123
Duration: Min: 7 hours 0 minutes Max: 9 hours 50 minutes Subtopics: 3-D Seismic Techniques: An Overview 3-D Seismic Data Acquisition 3-D Seismic Data Processing 3-D Interpretation Basics 3-D Interpretation in Practice Overview of 3-D Volume Visualization 4-D Seismic Applications 3-D and 4-D Seismic: References and Additional Informat ion Exercises and Solut ions Topic 60 of 123
Duration: Min: 3 hours 10 minutes Max: 4 hours 10 minutes Subtopics: Production Systems Inflow Performance Relationship Vertical Lift Performance Flowing Well Performance Fluid Flow and t he Production System: Reference Sect ion Topic 87 of 123
Duration: Min: 7 hours 20 minutes Max: 12 hours 0 minutes Subtopics: Secondary Recovery: Waterflooding and Gas Injection Enhanced Recovery: Miscible Flooding Improved Recovery Processes: References and Addit ional Information Topic 92 of 123
Duration: Min: 7 hours 30 minutes Max: 12 hours 10 minutes Subtopics: Reservoir Simulation Reserves Estimation Reservoir Modeling and Reserves Evaluation: References and Additional Information Topic 93 of 123
Duration: Min: 5 hours 40 minutes Max: 8 hours 50 minutes Subtopics: Evaluat ion of Naturally Fractured Reservoirs Reservoir Management of Mature Fields Issues in Reservoir Management : References and Additional Informat ion Topic 94 of 123
IPIMS
Action Learning Course Catalog
In this case our target is at Bass basin, offshore Australia. Basin depositional models indicate that probable reservoir sands are now within the oil window, giving deep unexplored port ions of the Bass basin considerable petroleum potent ial. The survey objective is to illuminate all Paleocene formations trough the whole area wit h 48 fold coverage near structural traps. For this exercise t he complexities of shot interval estimation due to vessel speed and air-gun recovery are not taken into account. The Assignment Pages should be done sequentially as all answers could be used as input for subsequent questions. So, t ake notes of all your findings during the completion of t his exercise.
Data Provided: Six 2D seismic lines Well A Info (TD=11940 ft), Sonic log, gamma ray log, density log, check shot survey Well B Info (TD=12585 ft) Map with seismic lines and wells locat ion The assignment should be done sequent ially as all answers could be used as input for subsequent questions. So, take notes of all your findings during the completion of this exercise.
In other words, we need t o det ermine , respectively, the oil and gas in place, the reserves, and the production rate. Your job in this assignment scenario is to review the reservoir data t hat have been collected to t his point and estimate the original hydrocarbon in place using volumetric and mat erial balance met hods, qualitatively evaluat e the reservoir drive mechanisms, and estimate the reservoirs primary recovery factor
Once t he structure, thickness, porosity and permeability maps are obt ained, t he data need t o be discretized according to the gridding system used. Fluid properties are entered into the model either using a dat a table or in the form of a correlation. For multi-phase flow problems, relative permeability relationships and capillary pressure curves also need to be obt ained. Models are typically initialized with respect to t he water/oil or gas/oil contact depths and a reference datum-level pressure value. For the initialization, the simulator is run unt il the hydrostatic equilibrium of the existing phases is established. Validation of the model requires a detailed production history of all wells in the reservoir. The production data should contain information about open int ervals, well stimulations and product ion rate of each phase (oil, gas, water). Aft er the model is history matched against the existing production data, it can be used to predict future reservoir behavior for different development scenarios. Keep in mind that these predict ions are only as good as the basic input that was ent ered int o the model. Your assignment here is to gat her all the iso-surface maps and fit a body-centered grid on top of the reservoir structure. You also need t o collect all the PVT data that will be used during the simulation.
By the time you complete this assignment, you should be able t o acquire and analyze pressure data, PVT reports, production records, injection records, production tests, fluid sampling, injectivity tests, and other information for the purpose of monitoring reservoir behavior. The explorat ion/appraisal program for this reservoir is currently in its third year. So far, four wells have been drilled: 4E1-NE, 5C1-SW (suspended), 2A5-NE and 5A1-SW.
Case 1a
Case 2a
Case 3a
11
10
15
The simulator runs used to generate these cases were based on the following assumptions:
Volumetric (closed pressure boundary) reservoir. Production begins in the first production year at the MDR, even though the reservoir actually produced at low rates under test conditions during t he exploration/appraisal stage. Average init ial production per well = 1500 STB/D [apx. 240 m3/D]under t he assumed reservoir parameters, this appears to be the maximum natural flow rate that is sustainable for a significant time period. In this assignment, you will compile the available informat ion and generate net discounted cash flow predictions for each of t hese cases. You will then evaluate each case in terms of its primary economic indicators, taking into account the sensitivity of t he evaluation t o uncert ainties in t he input parameters. NOTE: An MS Excel spreadsheet, Proj_Template, has been included as a reference for this assignment . You may use this spreadsheet to enter input paramet ers and run economics for each Case. If you do so, be sure to save each case as a separat e file, because you will be referring back t o it as you progress t hrough the assignment .
Petroleum Online
Course Catalog
All Sectors
Oil and Gas Industry Overview (IHRDC_PO_I1)
Description: A comprehensive overview of the industry; learn what petroleum is, where it comes from and how it affect s all of our lives on a daily basis. Become familiar with the various phases of the Oil and Gas Value Chain upstream, midst ream and downstream t he key industry players, the basics of oil and gas supply, demand and pricing and the challenges that t he industry faces as demand for t hese important form of energy grows by 50% in the next 25 years. Duration: 2:00:00 hrs Outline: Overview Crude Oil and Natural Gas: From Source to Final Products Chemistry of Hydrocarbons Origins of Crude Oil and Natural Gas Petroleum Migration and Accumulation Petroleum Reservoirs Separation and Treatment of Produced Oil and Gas Gas Handling and Processing Crude Oil Refining Petrochemicals Measurement Units and Conversion Factors Crude Oil Measurement Oil Quality: API Gravit y Natural Gas Measurement Gas Liquids and Petroleum Product Measurement Energy Cont ent and Equivalency Thermal Energy Equivalency: Hydrocarbon Price Equivalency: Conversion Table and Electronic Calculator Oil and Gas Value Chain Upstream Sect or Negotiation of Upstream Agreements Exploration Field Development Long-term Production Wholesale Hydrocarbon Markets Midstream Sector Crude Transportation Refining of Crude Oil Midstream Natural Gas Value Chain Gas Processing Natural Gas Pipeline Transportation and Storage Downstream Sect or Downstream Natural Gas Value Chain Main Global Players in the International Petroleum Industry OPEC Vertically Int egrated Global Companies World Primary Energy Markets and the Role of Hydrocarbons Energy Supply and Demand Fundament als Energy Demand Energy Supply Crude Oil Supply, Demand and Cross-border Trade Natural Gas Reserves Natural Gas Supply, Demand and Cross-border Trade Natural Gas Prices Emerging Commodity Price Final Thoughts Important Oil and Gas Statistical References Websites of Importance Acknowledgments Module 1 of 14
Upstream Sector
Upstream Oil and Gas Agreements (IHRDC_PO_I2)
Description: A comprehensive overview of the industry; learn what petroleum is, where it comes from and how it affect s all of our lives on a daily basis. Become familiar with the various phases of the Oil and Gas Value Chain upstream, midst ream and downstream t he key industry players, the basics of oil and gas supply, demand and pricing and the challenges that t he industry faces as demand for t hese important form of energy grows by 50% in the next 25 years. Duration: 2:00:00 hrs Outline: Overview Historical Perspective Methods for Obtaining a Host Government Agreement Four Types of Exploration Agreements The Concession Agreement US Offshore License Agreement West Africa Concession Agreement Additional Oil Entitlement Participation of National Oil Company: Working Interest Options Training Commitment and Other Forms of Sustainable Development The Production Sharing Cont ract Fiscal Terms Risk Service Agreements Natural Gas Discoveries: Post -Discovery Negotiations Joint Operating Agreements Nicola Case Study Agreement Stages Costs During Exploration Work Program and Relinquishment of Blocks Field Production and Development Costs Concession Agreement Sandland Business Game Summary Glossary of Terms Model Form for International Joint Operating Agreement Module 2 of 14
Upstream Sector
Petroleum Geology and The Exploration Process (IHRDC_PO_I3)
Description: Upstream agreement s define the legal, business and working relationships that exist between companies that explore for and produce oil and gas and the government agencies or privat e part ies t hat own the mineral right s. Learn how an oil and gas lease is negotiated wit h a landowner in the U.S. and then analyze the two major forms of agreements used by host count ries t he Concession Agreement and the Production Sharing Contract. Duration: 2:00:00 hrs Outline: Overview Fundamentals of Petroleum Geology Building of Sediment ary Basins Sedimentary Environments Sedimentary Rock Properties: Porosity and Permeability Formation of Crude Oil and Natural Gas Petroleum Migration and Accumulation Petroleum Reservoirs and Reservoir Traps Reservoir Seals Summary The Exploration Process Broad Surveying Techniques Existing Well Data Geophysical Surveying and the Seismic Reflection Method Conducting a 2D Seismic Survey Seismic Survey of the Pam Basin 3D and 4D Seismic Surveys Economics of the Pam Basin Prospect Summary References Module 3 of 14
Upstream Sector
Drilling and Well Completions (IHRDC_PO_I4)
Description: Examine the geological conditions that make for a good petroleum prospect, and learn why oil and gas are found in some places and not ot hers. Also learn the st ep-by-step process that exploration t eams follow t o identify projects, from the initial surface reconnaissance to the drilling of exploratory wells. Duration: 2:00:00 hrs Outline: Overview Drilling Objectives Surface and Subsurface Environments Rig Counts Drilling Technology Phases of Well Construction Well Planning Init ial St eps Authorization for Expenditure (AFE) Environmental and Regulatory Considerations Support and Logistics Drilling Rig Procurement Drilling Contract s Well Design Subsurface Pressure and Temperature Hole Sect ions Well Trajectory Deviation Control Directional Drilling Horizontal Drilling Geosteering Multilateral Wells Drilling Operations Rig Systems and Equipment Hoist ing and Rotating Systems Circulating System Well Control System Power Generation and Transmission System Types of Drilling Rigs Onshore (Land) Rigs Offshore Rigs Subsurface Drilling Equipment Drill String Components Drill Bit s Drilling Procedures Drilling Problems Remote Monitoring and Operations Support Formation Evaluation and Testing Well Completion Completion Design Well Stimulation Production Tubing Wellhead and Surface Flow Control Equipment Summary References Additional Resources Acknowledgments Module 4 of 14
Upstream Sector
Field Development and Production (IHRDC_PO_I5)
Description: The development and production of an oil or gas field is among the most involved and challenging business undertakings. Learn the st eps involved in field development, from its initial planning stages, through reservoir analysis, subsurface design and const ruction of surface facilities. This module also covers components of long-term production, reservoir management and facilities maintenance. Duration: 2:00:00 hrs Outline: Overview Reservoir Management Objectives Hydrocarbons in Place Recovery Factor Oil and Gas Reserves Primary Recovery Improved Recovery Production Schedule Optimal Design Rate Reservoir Description and Characterization Reservoir Parameters Geology and St ructure Rock and Fluid Properties Pressure and Temperature Data Acquisition, Interpretation and Analysis Geological and Seismic Interpretations Well Logs and Core Dat a Well Tests Production Data Integrated Reservoir Characterization Reservoir Mapping and Reserves Evaluation Subsurface Maps and What They Tell Us Reserves Definit ons and Classificat ions Reserves Evaluation Methods Uncertainties in Reserves Evaluation Monte Carlo Analysis / Probablist ic Represent at ion of Reserves Reservoir Modeling Object ives Elements of a Simulation Study Subsurface Development Plan Reservoir Performance Natural Drive Mechanisms Improved Recovery Processes Well Product ivity Production System Overview Flowing Well Performance Art ificial Lift Completion and Production Planning Estimating Field Performance Field Development Studies Surface Development Plan Surface Facilities General Considerations Onshore Facilities Offshore Facilities Economic Evaluation and Field Management Cash Flow Analysis Field Management Example Cost Estimating and Scheduling Field Management Example Operating Cost and Financial Assumptions Field Management Example Health, Safety and Environmental Considerations Health and Safet y Hazards in Field Operations
Upstream Sector
Field Development and Production (IHRDC_PO_I5)
Safety in Day-to-Day Operations Emergency Preparedness Environment Issues in Field Development and Product ion Regulatory Considerat ions Summary References Appendix Module 5 of 14
Upstream Sector
Upstream Gas: From Exploration to Wholesale Markets (IHRDC_PO_I13)
Description: Devot ed to the upstream gas value chain, this module begins with an overview of the significant gas properties and shows how a gas prospect is discovered and then developed into a viable producing entity. Import ant topics include the est imat ion of resources and reserves, field design process and surface facilit ies required to satisfy gas market specifications. It ends with a summary of the nature of the wholesale gas and gas liquids markets in various countries and typical wholesale agreement s. Duration: 2:00:00 hrs Outline: Overview Basic Gas and Gas Liquid Properties and Terminology Gas and gas liquids composition and properties Definition of industry terms: LNG, LPG, NGLs, CNG Gas Industry Value Chain with Emphasis on the Upstream Sector Upstream Petroleum Project Management Stages and Workflow Background on two gas exploration prospects Location Landowner or Host Count ry Exploration Agreements Technical Support for the Prospect Potential Gas Markets Demand, Timing, Sale Point, Prices and Contract Terms Project Planning and Economics Exploration and Field Development Plan and Schedule Reserves, Production, Rates, CAPEX, OPEX, IRR Permit s and Authorizations Required. HSE Issues Risk Analysis:Exploration, Development, Production, Market, Government Partner Issues Exploration of gas prospects Gas Exploration Basics Exploration Plan: Costs and Schedule Exploration well plan, evaluation and expect ed costs Results of Explorat ion Review of Reserves Wholesale Gas Markets and Project Market Options Project Economics Authorization to Move t o Next Stage Planning Gas Field Development Review of Alt ernative Subsurface Development Plans Optimization of Subsurface Development Plan Preparing Surface Facilit ies Plan Environmental and Social Impact Report Sources of Project Capital: Debt and Equity Project Partner Agreements Finalizing Gas Sales Contract Obtaining Government and Other Permits Project Management Plans Authorization to Move t o Development Development of New Discoveries Implementing t he Development Plan Project Management Issues: Scope, Schedule, Cost, Quality, Communications, Risks and Procurement Engineering, Procurement and Construct ion Agreement Final Costs and Timing Managing the Production Cycle Managing the Field Production Life Cycle Operations and Maintenance of Facilities Monitoring Well and Reservoir Performance Adding Wells and Compression Reservoir Management Managing Sales and Customer Relations Financial and Partner Report ing Summary of the Out come of the Two Prospects Summary of Case Studies and Drivers of Upstream Gas Success References
Upstream Sector
Upstream Gas: From Exploration to Wholesale Markets (IHRDC_PO_I13)
Module 6 of 14
Midstream Sector
Marketing and Trading of Crude Oil (IHRDC_PO_I6)
Description: Geological studies and seismic surveys can indicate an oil or gas prospect, but the only way to know if that prospect contains oil or gas is t o drill wells. Get an introduction to the basics of the rotary drilling process and learn the dramatic advances in drilling technology that have taken place in recent years. Duration: 2:00:00 hrs Outline: Overview Changing Nature of the Crude Oil Market Control of the Market by the "Majors" Shared Control The Opec Transition Price Shock of 1973 World Recession Nationalization, Market Transformation and New Discoveries Price Shock of 1979 Falling Demand Market-Related Crude Pricing Advent of Spot Markets Crude Oil Pricing Today Marker Crudes Crude Oil Assay Price Reporting Pricing of Other Crudes Use of the Futures Markets for Price Formation The Role of OPEC in Price Formation Fundamentals of a Physical Crude Oil Contract Seller / Buyer Relationship Title Transfer Arrangements / Point of Sale Other Contract Terms Typical Price Setting Negotiation of Physical Contracts Stages in the Negotiation of a Crude Contract Contract Examples Colombia Crude Sale to Unspecified End User Sale of Crude t o a Refiner in the Caribbean Nigerian Crude Sale to Trader Fundamentals of Financial Derivatives Forward and Future Contracts Crude Contracts Offered by Financial Exchanges How a Fut ures Contract Works General Feat ures of the Oil Futures Market Use of Derivatives in Price Risk Management Hedges: Buy or Sell Crude Oil SWAPS: Convert Variable Price t o a Fixed Price Options: Setting a Floor or Ceiling Price Typical Players In The Petroleum Derivatives Markets Trading of Crude Oil: Using Both Physical and Financial Contracts Summary References Exhibits Module 7 of 14
Midstream Sector
Crude Oil Transportation and Storage (IHRDC_PO_I7)
Description: Like ot her commodities, t he market determines the value of crude oil. Examine how crude oil markets and pricing are established based on global and regional supply and demand, how organizations such as OPEC affect t hese market s on a wholesale level. Duration: 2:00:00 hrs Outline: Overview Crude Oil Pipelines System Components Examples of International Pipelines Phases of Pipeline Development Pipeline Operat ions Pipeline Tariffs Batching Pipeline Maint enance Pigging Pipeline Inspection Corrosion Prevention Pipeline Safety Crude Oil Storage Temporary Storage of Crude Oil Strategic St orage of Crude Oil Nicola Case study: Pipeline and Storage Decisions Oil Tankers Tanker Sizes Tanker Classifications Trade Routes Chokepoints Demand and Supply Development of the World Tanker Trade Ownership and Hiring of Tankers Tanker Rates Worldscale Calculation Tanker Safet y Nicola case study: Shipping Decision Other Forms of Crude Oil Transportation References Acknowledgments Module 8 of 14
Midstream Sector
Midstream Gas: Gas Processing, Transportation and Load Balancing (IHRDC_PO_I14)
Description: The module covers t he midst ream gas value chain; essentially, the t ransportation of gas in pipelines and LNG ships and the balancing of market swings through the use of gas st orage facilities. The pipeline section focuses on design, operations and t ariffs, the LNG sect ion centers around the design and economics of the LNG value chain from liquefaction to receiving t erminals and the load balancing section summarizes the various options available to manage the pipeline swings between gas supply and market demand and their typical costs. Duration: 2:00:00 hrs Outline: Overview Gas Processing Gas Processing Terminology Properties of Natural Gas & Natural Gas Liquids Surface Facilities Key Products of Natural Gas Processing Ethane Propane Iso-Butane Normal Butane Natural Gasoline Gas Processing Opt ions Gas Processing Systems Markets for Gas Liquids Global Supply and Demand Natural Gas Pipelines Gas Pipeline History and Milestones Global Pipeline Infrastructure North America South America Europe Former Soviet Union Asia Australia Pipeline Design Wall Thickness Composite Reinforcement Capacity vs. Diameter Capacity vs. Operating Capacity Transmission System Design Pipeline Economics Development Process Onshore Offshore Pipeline Tariff Struct ure Regulated Market Deregulat ed Market History of the United St at es History of the United Kingdom Liquified Natural Gas LNG Value Chain LNG History and Milestones LNG Process Liquifact ion LNG Trains Transporation Regasification LNG Economics LNG Markets & Trade Load Balancing & Underground Gas Storage Load Balancing Applications Load Duration Curve Winter Flow Patt ern Underground Storage Options
Midstream Sector
Midstream Gas: Gas Processing, Transportation and Load Balancing (IHRDC_PO_I14)
Underground Storage Capacity & Trends Thomas Corners Gas Storage Case Study Surface Storage Options LNG Peakshaving Interruptible Customers Pore Storage Withdrawal Summary References Module 9 of 14
Midstream Sector
Refining and Product Specifications (IHRDC_PO_I8)
Description: Every day, some 85 million barrels of crude oil are transported from producing fields to major refining centers, many of which are located hundreds or t housands of miles apart. Learn how, and at what cost, crude oil is transported in pipelines and tankers t he two most practical and economical methods for moving large volumes of crude oil over long distances. Duration: 2:00:00 hrs Outline: Overview Crude Oil Characteristics Crude Oil Chemistry Paraffins (Alkanes) Olefins and Aromatics Naphthenes Heating Value of Hydrocarbons Boiling Points of Hydrocarbons Volume Changes during Refining Crude Quality: API Gravity and Sulfur Cont ent API Gravity Sulfur Cont ent Marker Crudes and Pricing Benchmarks Crude Quality: Yield of Petroleum Fractions The Refining Process Crude Yields and Product Demand Functions of a Refinery Hydroskimming Refinery Cracking Refinery Deep Conversion Coking Refinery Refinery Complexit y Non-Refined Petroleum Supply/Blend Streams Ethanol Bio-Diesel Gas-t o-Liquids Refining Economics Cost of Crude Oil and Value of Petroleum Product s Impact of Refining Complexity on Refining Margins Impact of Refining Capacity on Refining Margins Refinery Case Study: Addition 100,000 b/d Delayed Coker Fut ure Trends Health, Safety and Environmental Considerations Health and Safet y Environment Summary References Module 10 of 14
Downstream Sector
Marketing & Distribution of Petroleum Products (IHRDC_PO_I9)
Description: Once crude oil has been refined into transportation fuels, heating oil, lubricants and other products, it must be marketed and distributed to commercial and retail customers. In t his module you will learn how refined product s make their way to pipelines, t erminals, service stations and ot her outlets where the profits are being made in this downst ream sect or of the industry and the economics of the modern gasoline super-st at ion. Duration: 2:00:00 hrs Outline: Overview Petroleum Products and Services Fuels for Transportation and Heating Gasoline and Diesel Composition Performance Characteristics Kerosene (Aviation) Fuel Oils (Marine) Heating Fuels Liquefied Petroleum Gases (LPGs) Developments in Fuels, Bio-Fuels and Fuel Cells Non-fuel Specialty Products and Streams Lubricants and Greases Engine Lubricants Transmission Lubricants Indust rial Oils Greases Bit umens Chemicals and Solvents Other Products The Marketplace for Petroleum Products Retail Customers Commercial Customers Basics of Marketing Petroleum Products Marketing Segmentation and Customer Focus Retail Sector Commercial Sector Mobil Case Study Synopsis Worldwide Demand and Pricing for Petroleum Products Products Markets in Europe Product Markets in North America Products Markets in Asia Pacific The Downstream Value Chain: From Refinery to Final Sale Manufact uring of Petroleum Products Product Transport at ion, Storage and Distribution Importing Products Using Product Carriers Intermediate Bulk St orage Regional Transport at ion, Additives and Branding Product Pipelines Barges Rail Transportation Truck Transportation Market Out lets:Wholesale, Commercial and Retail Downstream Petroleum Examples Spain and New England CLH Distribution System Globals Value Chain Pricing Along the Downstream Value Chain Product Market Complexity and Competition Petroleum Distribution Costs and Margins Profit Margins at the Retail Service Station The Modern Gasoline Station Health, Safety and Environmental Considerations Summary References
Downstream Sector
Marketing & Distribution of Petroleum Products (IHRDC_PO_I9)
Module 11 of 14
Downstream Sector
Downstream Gas: Gas Distribution, Marketing & Trading (IHRDC_PO_I10)
Description: This module covers the downstream gas value chain including gas distribution, t he key gas market sectors and the manner in which gas supply is managed and sold into t he retail market. Emphasis is also placed on the nat ure of the gas markets in different regions of the world. The gas distribution coverage includes the design of a typical gas distribution system, the services it provides, typical distribution tariffs and billing structure. Gas markets discussed include residential, commercial, industrial, power generation, vehicle fuel and petrochemicals. Gas marketing and trading is introduced through the strategy t hat a "typical" gas distribution company follows in managing its gas supply in an "open access" gas industry environment. Duration: 2:00:00 hrs Outline: Overview Gas Distribution LDC Distribution System Regulation Deregulat ion LDC Supply System Model Distribution Operations Gas Service Functions Technologies in Gas Distribution LNG Receiving & Vaporization Facility LNG Truck Local LNG St orage Gas Distribution Markets Ident ification of Markets Major Classes of Gas Market s Assessing Market Demand Sources of Market Information Gas Supply Economics Natural Gas Pricing Direct Markets Power Generation Indust rial Retail Markets Resident ial Commercial Vehicle Fuel Petrochemicals Power Generation Indust rial Gas Trading Regulation Deregulat ion Convergence "Open Access" Henry Hub Gas Daily Index Basic Deal Types Physical Gas and Measure Exposure Hedging Fixed-Price Risk Hedging Basis Risk Exchange and OTC Trading Summary References Module 12 of 14
Downstream Sector
Overview of Petrochemicals (IHRDC_PO_I11)
Description: Crude oil, like other raw materials, has few practical uses in and of itself. It s value lies in t he products that can be ext racted from it . Learn how crude oil is processed into commercial products through various refining processes. Also explore why some refineries are more complex t han others and what business decisions go into each days refinery run. Duration: 2:00:00 hrs Outline: Overview: What are Petrochemicals? Characteristics of the Petrochemical Industry Global Nature of the Industry Common Specifications for most Products Readily Available Technology Large Scale, Capital Intensive Key to Success The Seven Basic Petrochemical Building Blocks Product Families and End-Uses Methane Ammonia Methanol Gas-t o-Liquids (GTL) Olefins Ethylene Propylene Butadiene The Aromatics Benzene Toluene Xylenes Petrochemical Plant Economics Components of Capital Investment Owners Project Cost s Tot al Fixed Investment Components of Product ion Costs Variable costs Fixed Costs Cash Cost of Production Depreciat ion Tot al Cost of Production Return on Capital Investment Required Plant Gate Price Economics of a Mega-Met hanol Project Why Invest in Petrochemical? Price Sett ing Mechanisms Demand Limited Scenario Production Limited Scenario Profitability Cycles Major Indust ry Issues Feedstock Costs Globalization and International Competit iveness Environmental Regulations Case Studies and Project Decriptions References Books Associations Selected Petrochemical Consulting Companies Selected Internet Sites with Petrochemical Industry Information Acknowledgments Module 13 of 14
All Sectors
Oil and Gas Business Game (IHRDC_PO_I12)
Description: Nicola, a dynamic Business Simulat ion Game, is used to int egrate the subject matter of each "Cont ent Module" to recreate the challenge of discovering, producing, and market ing oil and gas to learn where value, in the form of financial performance, is creat ed along the value chain. Duration: 2:00:00 hrs Module 14 of 14
Business Essentials
Course Catalog
Finance
Overview of Finance (IHRDC_BEES_FIN0101)
Description: Provides background on the financial environment by familiarizing you wit h it s major characteristics, definitions, and functions. You will learn how financial decisions fit int o the world of business decision-making and how these choices pose problems, challenges, and opportunities for organizations and individuals. Duration: 4:00:00 hrs Courses: Types of Business Organizations Wealth and Profit Maximization Business Ethics and Social Responsibility Where Does t he Finance Function Fit In and What Are It s Typical Responsibilities? Agency Relationships: Stockholders and Managers Motivating Managers The Five Key Principles of Financial Management Financial Markets and Institutions Financing and Operations Growth The Stock Market The Cost of Money: Interest Rates and Required Rates of Return Vocabulary Game Self-Assessment Self-Assessment Re-Test For Further Reference Module 1 of 35
Finance
Accounting Concepts and Financial Statement Analysis (IHRDC_BEES_FIN0201)
Description: Develops an understanding of account ing concept s and the ability to int erpret major financial accounting statements and financial management tasks. Finance is essentially a type of applied economics that makes extensive use of accounting concepts and definit ions. Duration: 4:00:00 hrs Courses: Annual Reports and Financial Statements The Balance Sheet The Income Statement Retained Earnings and Statement of Cash Flows Financial Analysis: Using Ratios Financial Ratios and Benchmarking Vocabulary Game Self-Assessment Self-Assessment Re-Test For Further Reference Module 2 of 35
Finance
Time Value of Money Principles (IHRDC_BEES_FIN0301)
Description: Learn the basic techniques (compounding, discounting, present and future value) used in evaluating all financial decisions, and t heir cash flow implications. Duration: 4:00:00 hrs Courses: Understanding Time Lines Calculating Fut ure and Present Values Annuities and Perpetuities Cash Flow Possibilities Interest Rates and the Power of Compound Interest Vocabulary Game Self-Assessment Self-Assessment Re-Test For Further Reference Module 3 of 35
Finance
Risk and Return (IHRDC_BEES_FIN0401)
Description: Reviews the many different ways to measure risk when considering a decision, each of which will produce different results. In this module you will learn about the relationship between risk and return and explore the benefit s of diversification. Duration: 4:00:00 hrs Courses: Fundamentals Different Types of Risk Investments and Variability of Retur Risk and Invest ment Decisions Calculating risk and rat es of return Diversificat ion and Risk Other Concept s: CAPM, APT, VaR Self Assessment Self Assessment Re-Test Module 4 of 35
Finance
Budgeting (IHRDC_BEES_FIN0501)
Description: Learn the basics of budgeting, including the varying t ypes of budgets, and explore the benefits of budgeting. Duration: 4:00:00 hrs Courses: Budget Basics Strategic Budgeting The Master Budget Operating Budgets Managing the budget process Vocabulary Game Self-Assessment For Further Reference Module 5 of 35
Finance
Practical Tools for Planning and Control (IHRDC_BEES_FIN0601)
Description: Considers t he practical tools of finance and accounting for decisionmaking by organizat ions. You will learn about cost benefit analysis, return on invest ment (ROI), fixed and variable costs, breakeven and CVP (cost-volume-profit) analysis, tracking and performance measures, as well as the Balanced Scorecard and its uses. Duration: 4:00:00 hrs Courses: Cost-Benefit Analysis Return on Investment and Payback Period Fixed and Variable Costs Breakeven analysis and Cost Volume Profit (CVP) analysis Breakeven analysis- An Example Tracking and Performance Balanced Scorecard Measurements Vocabulary Game Self-Assessment Self-Assessment Re-Test For Further Reference Module 6 of 35
Finance
Valuing Real Assets (IHRDC_BEES_FIN0701)
Description: Addresses the use of t he basic principles of finance t o det ermine the desirability of acquiring an asset that is expected to produce a future cash flow stream. The term capit al budget ing is t he name given to t his process. You will also learn to conduct a financial analysis of an asset or project under consideration. Duration: 4:00:00 hrs Courses: What is Capital Budget ing? Estimating Cash Flows Assessing Project Risk Net Present Value and Internal Rate of Return Useful Tools for Capital Budget ing Self-Assessment Self-Assessment Re-Test For Further Reference Course Feedback Module 7 of 35
Communications
Effective Communication (IHRDC_BEES_COM0101)
Description: Focuses on improving business writ ing. You will learn how to write clearly and directly for your audience. Duration: 2:30:00 hrs Courses: Why Effective Communication Matters How We Communicate The Problem with Jargon Factors for Effective Communication Knowing Your Audience Ethical Communication Self-Assessment Module 8 of 35
Communications
Organizing and Structuring (IHRDC_BEES_COM0201)
Description: Reviews purposeful writ ing, as well as organizing and structuring your writing. You will learn how to brainstorm, conduct research, and deal with writ er's block. Duration: 2:30:00 hrs Courses: Writing and Communicating with Purpose Who is your audience? What is your message? Out lining: Formal and Informal Brainstorming Techniques Research Overcoming Writer's Block Self-Assessment Module 9 of 35
Communications
Writing Effectively (IHRDC_BEES_COM0301)
Description: You will learn how to be a better writer and how to revise your writing to make it purposeful and effective. Duration: 2:30:00 hrs Courses: Writing Concisely Writing Quickly Writing Quickly: Struct ure Revising Your Writing Revising: Jargon Email Additional Resources: Business Writ ing Self-Assessment Module 10 of 35
Communications
Presentations Basics (IHRDC_BEES_COM0401)
Description: Teaches you the basics of how t o organize, st ructure and create presentations. Since many organizations use PowerPoint as a way of communicat ing information, t his module offers advice and guidance on the most effect ive and persuasive uses of PowerPoint. Duration: 2:30:00 hrs Courses: Why Effective Communication Matters Understanding How We Communicate Presentations: Visual Aids PowerPoint Presentations: Graphic Rules of Thumb PowerPoint Presentations: Creating Summary Slides PowerPoint Presentations: Creating Summary Slides II Vocabulary Game Self-Assessment Module 11 of 35
Communications
Purposeful Presentations (IHRDC_BEES_COM0501)
Description: Builds on Present at ion Basics and helps learners organize, structure and create presentations Duration: 2:30:00 hrs Courses: Organizing your Communication Organizing your Presentation: Forecast, Present and Echo PowerPoint Presentations: Other Visual Considerations PowerPoint Presentations: Creating a Present at ion Revising PowerPoint PowerPoint Presentations: Creating a Present at ion II Tips on Face-to-Face Presentations Additional Resources: Presentations Self-Assessment Module 12 of 35
Project Management
Introduction to Project Management (Fourth Edition) (IHRDC_BEES_PMT0101)
Description: This 1-module course was designed as a supplement al study guide for t he major content areas of Chapt ers 1 and 2 of A Guide t o the Project Management Body of Knowledge (PMBOK Guide), Fourth Edit ion. In this course, you will consider some of the organizational issues surrounding project management. You will review how different organizations handle the responsibilities of project management and will focus on t he entity known as a project management office, or PMO. You will also learn how organizational structure can play a key role in the success or failure of project management. Duration: 3:30:00 hrs Courses: Presentation: Projects in Context: Understanding the Bigger Pict ure Presentation: St akeholders Presentation: Project Management Office (PMO), Resources, and Influences Presentation: Organizational St ructures Presentation: Project Life Cycle: Understanding Phases and Project Tendencies Best Practices: Select ing a Project Manager Best Practices: Project Manager Candidate Profile Review Interactive: PM Vocabulary Game Self-Assessment PMBOK Guide Chapter 1 and 2 Quiz Module 25 of 35
Project Management
Project Processes and Project Integration Management (Fourth Edition) (IHRDC_BEES_PMT0102)
Description: This course was designed as a supplemental study guide for the major content areas of Chapters 3 and 4 of A Guide to t he Project Management Body of Knowledge (PMBOK Guide), Fourt h Edition. In this course, you will be introduced to the five project management process groups and nine project management knowledge areas into which PMI sorts all project activities. You will also learn how processes in the Project Integrat ion Management knowledge area encourage relationships between project processes that keep the project's activities co-ordinated and on track for success. Duration: 3:30:00 hrs Courses: Presentation: Project Processes: An Integrat ed Flow Presentation: Project Management Processes, Project Management Process Groups, and Project Management Knowledge Areas Exercise: Process Groups And Their Const ituent Processes Presentation: Project Integration Management Presentation: Project Charter and Major Project Documents Presentation: Executing, Monitoring, and Closing Project Integration Management Processes Presentation: Handling t he Kick-Off Meeting Interactive: Vocabulary Game Self Assessment PMBOK Guide Chapter 3 Quiz PMBOK Guide Chapter 4 Quiz Module 26 of 35
Project Management
Project Scope Management (Fourth Edition) (IHRDC_BEES_PMT0103)
Description: This course was designed as a supplemental study guide for the major content areas of Chapter 5 of A Guide to the Project Management Body of Knowledge (PMBOK Guide), Fourth Edition. In this course, you will consider many of the key issues surrounding Project Scope Management. Duration: 3:30:00 hrs Courses: Presentation: Collect Requirements [ ] and Define Scope [ 2] Presentation: Create Work Breakdown Structure [ 3] Presentation: Verify Scope [ 4] and Control Scope [ 5] Best Practices: Project Review Reports and Meetings Best Practices: Updating Stakeholders Vocabulary Game Self-Assessment PMBOK Guide Chapter 5 Quiz Module 27 of 35
Project Management
Project Time Management (Fourth Edition) (IHRDC_BEES_PMT0104)
Description: This course was designed as a supplemental study guide for the major content areas of Chapter 6 of A Guide to the Project Management Body of Knowledge (PMBOK Guide), Fourth Edition. In this course, you will consider how to best plan and schedule activities. You will familiarize yourself wit h the various techniques used to calculate and analyze activity time estimates, including ways to estimate the duration of activities. Duration: 3:30:00 hrs Courses: Presentation: Defining Activities Presentation: Sequencing Activities Presentation: Estimating Activity Resources and Durations Exercise: Est imat ion Using PERT and Z-Score Presentation: Develop Schedule and t he Critical Path Met hod Exercise: Identifying t he Critical Path Best Practices: Crashing Best Practices: Scheduling Pract ice Vocabulary Game Self-Assessment PMBOK Guide Chapter 6 Quiz Module 28 of 35
Project Management
Project Cost Management (Fourth Edition) (IHRDC_BEES_PMT0105)
Description: This course was designed as a supplemental study guide for the major content areas of Chapter 7 of A Guide to the Project Management Body of Knowledge (PMBOK Guide), Fourth Edition. In this course, you will consider the general approaches to cost management, such as t he methods that are used to estimate and budget for project costs. You will also learn about the interrelationship of various cost control concepts and possible responses a project management team might make if a project is falling behind schedule or overrunning its budget. Duration: 3:30:00 hrs Courses: Presentation: Estimate Costs Presentation: Determine Budget and the Cost Performance Baseline Presentation: Cost Analysis and Cost Control Exercise: Evaluating Project Status Best Practices: Cost Estimating and Budgeting Interactive: PM Vocabulary Game Self-Assessment PMBOK Guide Chapter 7 Quiz Module 29 of 35
Project Management
Project Quality Management (Fourth Edition) (IHRDC_BEES_PMT0106)
Description: This course was designed as a supplemental study guide for the major content areas of Chapter 8 of A Guide to the Project Management Body of Knowledge (PMBOK Guide), Fourth Edition. In this course, you will learn how the project management t eam ensures t hat a project is complet ed at t he level of quality required by all the stakeholders. From customers to the performing organization, there are many inputs to the process. This course will explain how the project management team can plan for, execute, and monitor and cont rol quality. Duration: 3:30:00 hrs Courses: Presentation: Project Quality Management Overview and Plan Quality Presentation: Planning Tools and Techniques Presentation: Flowcharts Presentation: Perform Qualit y Assurance and Perform Quality Control Exercise: Choosing the Correct Tool Best Practices Mini-Case: Improving Public Improvements Vocabulary Game Self-Assessment PMBOK Guide Chapter 8 Quiz Module 30 of 35
Project Management
Project Human Resource Management (Fourth Edition) (IHRDC_BEES_PMT0107)
Description: This course was designed as a supplemental study guide for the major content areas of Chapter 9 of A Guide to the Project Management Body of Knowledge (PMBOK Guide), Fourth Edition. In this course, you will learn how to acquire and negotiate t he best staff, how to define roles and responsibilit ies in project documentation, and how to employ the essent ials of good people management . Duration: 3:30:00 hrs Courses: Presentation: Project Human Resource Management Presentation: Acquire Project Team Presentation: Develop Project Team Presentation: Manage Project Team Presentation: Conflict Management Best Practices Mini-Case: The Cycle Time Improvement Project Best Practices: Gathering Input for Decision-Making Best Practices: Web Resources on Group Dynamics Best Practices Mini-Case: Selecting a Decision-Making Approach Vocabulary Game Self-Assessment PMBOK Guide Chapter 9 Quiz Module 31 of 35
Project Management
Project Communications Management (Fourth Edition) (IHRDC_BEES_PMT0108)
Description: This course was designed as a supplemental study guide for the major content areas of Chapter 10 of A Guide to the Project Management Body of Knowledge (PMBOK Guide), Fourth Edition. In this course, you will learn about how project management t eams can effectively communicate with the project's various stakeholders. Duration: 3:30:00 hrs Courses: Project Communications Management and Communications Basics online Ident ify Stakeholders online Plan Communications and Distribute Information online Manage Stakeholder Expectations online Report Performance online Best Practices: Mini-case: Confronting Communication Challenges online Vocabulary Game online Self-Assessment test PMBOK Guide Chapter 10 Quiz Module 32 of 35
Project Management
Project Risk Management (Fourth Edition) (IHRDC_BEES_PMT0109)
Description: This course was designed as a supplemental study guide for the major content areas of Chapter 11 of A Guide to the Project Management Body of Knowledge (PMBOK Guide), Fourth Edition. In this course, you will define the core element s of risk management, including the risk register. You will also understand how risks are identified, prioritized, quantified and used in decision-making. Duration: 3:30:00 hrs Courses: Presentation: Plan Risk Management Presentation: Identify Risks Presentation: Perform Qualit at ive Risk Management Presentation: Perform Quantitative Risk Analysis Exercise: Perform Quantitative Risk Analysis Presentation: Plan Risk Responses and Monitor and Cont rol Risks Best Practices: Web Research Vocabulary Game Self-Assessment PMBOK Guide Chapter 11 Quiz Module 33 of 35
Project Management
Project Procurement Management (Fourth Edition) (IHRDC_BEES_PMT0110)
Description: This course was designed as a supplemental study guide for the major content areas of Chapter 12 of A Guide to the Project Management Body of Knowledge (PMBOK Guide), Fourth Edition. In this course, you will consider the various aspects of the Project Procurement Management knowledge area. Duration: 3:30:00 hrs Courses: Presentation: Plan Procurements Presentation: Conduct Procurements Presentation: Administer Procurements and Close Procurement s Exercise: Pinpointing the Procurement Process Presentation: Contract Negotiation Interactive: PM Vocabulary Game Self-Assessment PMBOK Guide Chapter 12 Quiz Module 34 of 35
Project Management
Project Management Practice Examination and Examination Strategies (Fourth Edition) (IHRDC_BEES_PMT0201)
Description: This Pract ice Exam covers the Project Management Inst itute's standard, A Guide to the Project Management Body of Knowledge (PMBOK Guide). The practice exam contains multiple-choice questions that provide a comprehensive review of t he PMBOK Guide. Duration: 3:30:00 hrs Courses: Practice Examination 1: PMBOK Guide Knowledge Practice Examination 2: PMBOK Guide Knowledge Project Management Professional (PMP) Exam Strategies Introduction t o the PMP Exam PMI's PMP Code of Professional Conduct Tips for PMP Exam Test Taking Key PMBOK Guide Content to Memorize Test Center Logistics Ending the Test Exam Strat egy Self-Assessment Module 35 of 35
Process Operations
BOILERS: Basic Principles and Types (IHRDC_OM_AOBBP)
Overview: This interactive training unit is designed to int roduce trainees to fundamental concepts related to industrial plant boilers. After completing this unit, t rainees should be able to describe the basic requirements for steam production and combustion and explain how a boiler produces steam. They should also be able to ident ify three types of heat t ransfer and explain how heat t ransfer occurs in a t ypical boiler. In addit ion, trainees should be able t o describe how water, combust ion gases, and steam flow t hrough fire tube and water tube boilers. Duration: 2 hrs Objectives: Principles of Operation State the basic requirements for steam production. State the basic requirements for combustion. Explain in general terms how a boiler produces steam. Heat Transfer Describe heat transfer. State three ways in which heat t ransfer can occur in a typical boiler. Ident ify problems t hat can interfere with proper heat transfer and t he effect of each on boiler operation. Boiler Types Name two basic t ypes of boilers. Describe the basic differences between fire tube and water t ube boilers. Describe how water, combustion gases, and st eam flow through fire tube and water t ube boilers.
Subjects: Principles of Operation Steam Production and Combustion Basic Boiler Operat ing Principles Heat Transfer Types of Heat Transfer Heat Transfer Problems Heat Transfer in a Boiler Boiler Types Fire Tube Boilers Water Tube Boilers Course 1 of 245
Process Operations
BOILERS: Combustion, Water and Steam (IHRDC_OM_AOBOW)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic principles associated with combustion in a boiler and t he flow of air and combustion gases during boiler operation. Aft er completing t his unit, trainees should be able t o identify t he elements needed for combust ion in a boiler, explain how fuel is delivered t o the burners, and describe the parts and operation of various types of burners. They should also be able to describe the air and gas flow path through a boiler and describe methods used to remove particulates and harmful gases from combustion gases. In addit ion, trainees should be able t o explain when and why vents, drains, blowdown valves, and soot blowers are used. Duration: 2 hrs Objectives: Combustion Equipment Describe the parts and operation of t ypical gas burners, oil burners, and stokers. Air Flow Ident ify some devices used to improve the efficiency of boiler operations. Explain how air flow is produced in a typical boiler. Explain why changes in boiler load require fuel and air adjustments. State why it is necessary to maintain a proper fuel-to-air rat io in a boiler. Describe the parts and basic operation of a t ypical rot ary air heater. Explain how rotary air heaters improve efficiency of boiler operations. Water and Steam Flow Explain how natural circulat ion occurs in a typical water tube boiler. Explain how controlled circulation occurs in a typical water tube boiler. Describe an economizer, why it is used, and how it improves efficiency. Name some devices commonly used to remove moisture from steam and how they operate.
Subjects: Combustion Equipment Gas Burners Oil Burners Stokers Air Flow Draft Fuel-t o-Air Ratio Air Heaters Water and Steam Flow Boiler Water Circulation Economizers Moisture Separat ors Course 2 of 245
Process Operations
CHEMISTRY: Basic Principles 1 (IHRDC_OM_AOCB1)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with the composition of matter and t he general characteristics of compounds, mixtures, and solutions. After completing this unit, t rainees should be able to identify the particles t hat make up an atom and describe two ways in which atoms form chemical bonds. They should also be able to explain what compounds and mixtures are, and how they differ from one another. In addit ion, trainees should be able t o describe what a solution is, calculate the weight s of materials in a percent-by-weight solution, and explain what a pH measurement represent s. Duration: 2 hrs Objectives: Introduction to Chemistry Define: mat erial, matter, mass, element, at om, prot on, neutron, and elect ron. Ident ify the particles that make up an at om. Define: valence electron and ion. Describe two ways in which at oms form chemical bonds. Compounds and Mixtures Define: compound and chemical reaction. Define mixture. Explain how compounds and mixtures differ from one another. Solutions Define: solution, solute, solvent , homogeneous, and concentration. Calculate the weights of the materials in a percent-by-weight solution, given the weight of the solution and t he percentage of solute. Explain what a pH measurement represents.
Subjects: Introduction to Chemistry Composition of Matter Valence Electrons and Chemical Bonds Compounds and Mixtures Compounds Mixtures Solutions Charact eristics Percent -by-Weight pH Measurements Course 3 of 245
Process Operations
CHEMISTRY: Basic Principles 2 (IHRDC_OM_AOCB2)
Overview: This interactive training unit is designed to familiarize trainees wit h the principles of chemical reactions, material balancing, and organic chemistry. After completing this unit, trainees should be able to use a chemical equat ion to explain what occurs during a chemical reaction, and how combustion reactions, replacement reactions, and neutralizat ion occur. Trainees should also be able to define material balancing, and describe the basic steps involved in balancing the materials represented in a simple equat ion. In addition, trainees should be able to explain what organic chemistry is and how some organic chemicals are named. Duration: 2 hrs Objectives: Chemical Reactions Ident ify three common types of chemical react ions. Define: chemical equation and chemical reaction. Use a chemical equation t o explain what occurs during a simple chemical reaction. Define endothermic and exothermic in terms of their application to chemical react ions. Explain how a combust ion reaction, replacement reaction, and neut ralization reaction occur. Explain how the acidity or alkalinity of a liquid is measured. Material Balancing Explain the meaning of material balancing. Ident ify the steps involved in balancing the materials represented in a simple equation. Given the actual weight of one mat erial in a reaction, use the relative weights of the atoms in the reaction to determine the actual weights of the other materials involved. Organic Chemistry Define organic chemistry. Explain how some organic chemicals are named.
Subjects: Chemical Reactions Chemical Equat ions Combustion Reactions Replacement and Neutralization Reactions Material Balancing Steps in Material Balancing Relative and Actual Weights Organic Chemistry Basis of Organic Chemistry Naming Organic Chemicals Course 4 of 245
Process Operations
CHEMISTRY: Material Balancing (IHRDC_OM_AOCMB)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with using balanced chemical equat ions to calculate the amounts of reactants and products in process reactions. After completing this unit , trainees should be able to explain what material balancing is, verify that a chemical equation is balanced, and use a balanced equation t o calculate the amounts of reactants and products in a reaction when the weight of one reactant is given. They should also be able to identify two basic factors that can limit the product ion of a process syst em, perform material balancing for a process system when reactant supply is the limit ing factor, and perform material balancing for a system in which a specific amount of product is to be produced. Duration: 2 hrs Objectives: Chemical Equations Explain the meaning of material balancing. Verify that a chemical equation is balanced. Define molecular weight and explain how to calculate the weight of a molecule. Calculate the amounts of reactants and products in a reaction when given t he weight of one reactant. Limiting Factors Ident ify two basic factors that can limit the production of a process system. Convert reactant supplies expressed as total amount s int o supply rat es. Determine the limiting factor of a process system that is being operat ed to produce as much product as possible. Perform material balancing for a process system when reactant supply is the limiting fact or. Perform material balancing for a system in which a specific amount of product is to be produced.
Subjects: Chemical Equations Equations Molecular Weights Actual Weights Limiting Factors Determining the Limiting Factor Determining Reactant Amounts Course 5 of 245
Process Operations
CHEMISTRY: Reaction Rates (IHRDC_OM_AOCRR)
Overview: This interactive unit is designed to familiarize trainees with basic concepts associated wit h the rates at which chemical react ions occur. After completing this unit, trainees should be able to describe two factors that determine the rates of react ions, and the effects of temperature, pressure, concentrat ion, and surface area on reaction rates. They should also be able to describe how catalysts affect reaction rates and how t emperature and pressure affect equilibrium react ions. Duration: 2 hrs Objectives: Reaction Rate Factors Define react ion rate. Explain how chemical reactions occur and describe two factors that determine the rates of react ions. Describe the effects of temperature, pressure, concentration, and surface area on reaction rates. Catalysts Define catalyst. Describe how adsorption catalysts work. Explain how some catalyst s can become poisoned. Describe how catalysts work by forming an intermediate product during a reaction. Equilibrium Reactions Define equilibrium and equilibrium point . Describe the effects of temperature and pressure on an equilibrium reaction. Describe one way that products can be stabilized.
Subjects: Reaction Rate Factors Chemical React ions Effects of Variables Catalysts Adsorption-Type Cat alysts Intermediate-Type Cat alysts Equilibrium Reactions Equilibrium Temperature and Pressure Stabilizing Products Course 6 of 245
Process Operations
COMPRESSORS: Centrifugal and Axial (IHRDC_OM_AOCCA)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with the parts and operation of cent rifugal and axial compressors. After completing this unit, trainees should be able to describe the main parts and the general operation of single-stage centrifugal compressors, mult istage centrifugal compressors, and axial compressors. They should also be able to describe the functions of compressor lubrication systems, seals, bearings, and common auxiliary devices. Duration: 2 hrs Objectives: Compressor Types Describe the basic operation of a centrifugal compressor. Describe the basic operation of an axial compressor. Describe the components and operat ion of a single-stage centrifugal compressor. Describe the components and operat ion of a mult istage centrifugal compressor. Describe the components and operat ion of an axial compressor. System Components Describe the function of a compressor lubrication system. Describe the functions of compressor seals and a seal oil system. Describe the function of bearings. Describe how drivers and couplings are used with compressors. Describe the function of an aftercooler. Describe the function of safet y valves and receivers in compressor systems.
Subjects: Compressor Types Introduction Centrifugal Compressors Axial Compressors System Components Lubrication, Seals, and Bearings Auxiliary Devices Course 7 of 245
Process Operations
COMPRESSORS: Introduction (IHRDC_OM_AOCIN)
Overview: This interactive training unit is designed to familiarize trainees wit h the operation of compressors and compressed gas systems. Aft er completing t his unit, trainees should be able t o describe two general types of compressors and the components and operation of a typical compressed air system. They should also be able to explain the hazards and safety precautions of compressors and compressed gas systems. In addition, trainees should be able to describe the functions of systems and devices t hat are commonly used with compressors and compressed gas systems. Duration: 2 hrs Objectives: Compressors and Systems Describe two general types of compressors. Describe some characterist ics t hat all compressors share. Ident ify the component s of a typical compressed air system. Describe the operation of a typical compressed air system. Describe hazards and safet y precautions associated wit h compressors. Describe hazards and safet y precautions associated wit h compressed gas systems. System Components Describe the function of a filt er. Describe the function of an air cooling system and a water cooling system. Describe the function of a lubricat ion syst em. Describe the function of an oil separator. Describe the function of a demister. Describe the function of a dryer. Describe the function of a receiver. Describe the function of an unloader. Describe the function of safet y valves.
Subjects: Compressors and Systems Compressors Compressed Air Systems Compressor Hazards System Components Filtering, Cooling, and Lubrication System Auxiliaries Course 8 of 245
Process Operations
COMPRESSORS: Operation of Centrifugal and Axial Types (IHRDC_OM_AOCOC)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with the startup, operat ion, and shutdown of centrifugal and axial compressors. After completing this unit, trainees should be able to describe the general functions of instrumentation and cont rol devices used with centrifugal and axial compressors. They should also be able to identify operat or responsibilities associated with st arting up, operating, and shutting down centrifugal and axial compressors. Duration: 2 hrs Objectives: Instrumentation and Control State the general feat ures of instrumentation and control devices used with centrifugal and axial compressors. Describe how instrumentation and control devices can maintain the values of a compressor's process variables. Describe how instrumentation and control devices can keep a compressor operating within a stable operat ing range. Operation Describe the general steps involved in preparing a compressor for st artup. Describe the general steps involved in warming up a compressor. Describe the general steps in starting gas flow to a compressor and bringing a compressor up to operating speed. Describe typical compressor operating checks. Describe some of the general steps involved in a compressor shutdown.
Subjects: Instrumentation and Control Functions Surge Control Operation Startup Operation and Shutdown Course 9 of 245
Process Operations
COMPRESSORS: Positive Displacement (IHRDC_OM_AOCPD)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with the operation of posit ive displacement compressors. After completing this unit, trainees should be able to identify the main part s and describe the general operation of various types of reciprocating and rotary compressors. They should also be able to identify operator responsibilities associat ed with starting up, operat ing, and shutt ing down compressors. Duration: 2 hrs Objectives: Compressor Types Ident ify the main parts of a reciprocating compressor. Describe the general operation of a reciprocating compressor. Ident ify different types of reciprocating compressors and describe their operation. Ident ify the main parts of a typical rotary compressor. Describe the general operation of different t ypes of rotary compressors. Compressor Operations Describe general checks that should be made before a compressor is started. Describe general procedures for starting up a compressor. Describe general checks that should be made while a compressor is running. Describe general procedures for shutting down a compressor. Describe general procedures for putting a portable compressor in operation.
Subjects: Compressor Types Reciprocating Compressors Reciprocating Compressor Variations Rotary Compressors Compressor Operations Pre-Start up Checks Startup, Operation, and Shutdown Port able Compressors Course 10 of 245
Process Operations
DIAGRAMS: Basic Diagrams and Symbols 1 (IHRDC_OM_AODB1)
Overview: This interactive training unit is designed to int roduce trainees to plant system diagrams and diagram symbols. After completing t his unit, trainees should be able t o identify and describe the purpose of several kinds of system diagrams, and be able to describe the information found on each type. Trainees should also be able t o identify symbols commonly used on flow diagrams, and how to use a flow diagram to trace the flow paths of a system. Duration: 2 hrs Objectives: Types of Diagrams Ident ify and describe the purpose of equipment arrangement diagrams, elevation drawings, piping system (flow) diagrams, piping and instrument at ion diagrams (P&IDs), electrical diagrams, and legends. In general terms, describe t he informat ion found on each type of diagram. Flow Diagram Symbols Ident ify some basic symbols associated with flow diagrams. Ident ify symbols commonly used t o represent components in flow diagrams. Describe the basic operation of the components typically found in a fluid system. Reading Diagram Symbols Ident ify the four basic parts of a system. Ident ify the component s of a typical fluid system and relate them to their symbols and functions.
Subjects: Types of Diagrams Equipment Location Diagrams System Diagrams Flow Diagram Symbols Tanks, Pumps, and Valves Actuators Heat Exchangers Reading Diagram Symbols Block Diagrams Flow Diagrams Course 11 of 245
Process Operations
DIAGRAMS: Basic Diagrams and Symbols 2 (IHRDC_OM_AODB2)
Overview: This interactive training unit is designed to familiarize trainees wit h symbols commonly used on piping and inst rumentation diagrams (P&IDs) and electrical one-line diagrams. After complet ing this unit, trainees should be able to ident ify instrument symbols and line symbols used in P&IDs, describe t he types of information typically found on a legend, and use a P&ID to locate t he components of a system. They should also be able t o identify symbols used on electrical one-line diagrams. Duration: 2 hrs Objectives: Piping and Instrumentation Diagrams Ident ify instruments using an identification chart. Ident ify line and instrument symbols used in piping and instrumentation diagrams. Using a System Diagram Describe the t ypes of information typically found on a legend. Locate the components in a boiler fuel oil system by identifying the symbols used to represent them. Electrical Diagrams Ident ify symbols commonly found on one-line electrical diagrams. Trace out a typical one-line diagram and briefly describe its connect ions.
Subjects: Piping and Instrumentation Diagrams Instrument Symbols Reading a P&ID Using a System Diagram Legends Using a System Diagram Electrical Diagrams Main Transformer Section Load Center Section Course 12 of 245
Process Operations
DIAGRAMS: Flow and Electrical (IHRDC_OM_AODUF)
Overview: This interactive training unit is designed to familiarize trainees wit h the use of flow diagrams and electrical one-line diagrams. Aft er completing t his unit, trainees should be able t o use a flow diagram to trace the flow of materials t hrough a syst em, and use a flow diagram and a valve lineup checklist to line up valves in a system. They should also be able to use an electrical one-line diagram to learn the components and layout of an electrical system, and to determine how to isolate a piece of equipment for maintenance or repair. Duration: 2 hrs Objectives: Using Flow Diagrams Describe how flow diagrams can be used to become familiar with a system. Describe how flow diagrams can be used to line up valves. Describe the relationship bet ween flow diagrams and valve lineup checklists. Using Electrical Diagrams Describe how electrical one-line diagrams can be used to learn t he components and layouts of electrical systems. Describe how electrical one-line diagrams can be used to determine how to isolate equipment for maintenance and repairs.
Subjects: Using Flow Diagrams Learning a Plant System Lining Up Valves Using Electrical Diagrams Learning an Electrical System Isolating Equipment Course 13 of 245
Process Operations
DIAGRAMS: Piping and Instrumentation (IHRDC_OM_AODUI)
Overview: This interactive training unit is designed to make trainees familiar with the use of piping and instrument at ion diagrams (P&IDs). Aft er completing t his unit, trainees should be able t o describe the kinds of information t hat can be found on a P&ID and explain why t his information is useful. They should also be able to explain how to use P&IDs to troubleshoot system problems. Duration: 2 hrs Objectives: Introduction Describe the t ypes of information provided by P&IDs and explain why this information is useful. Describe how a P&ID can be used to become familiar with t he instrumentation associat ed with a system. Troubleshooting Describe how P&IDs can be useful in t roubleshooting problems.
Subjects: Introduction Information on P&IDs Learning a Syst em Troubleshooting Water Treatment System Problem De-Aerat or Syst em Problem Course 14 of 245
Process Operations
DISTILLATION: Basic Principles (IHRDC_OM_AODBP)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic principles of t he distillat ion process. After completing this unit, t rainees should be able to explain how changes in the state of matter relate to the distillation process and how these changes are affect ed by temperature and pressure. They should also be able to explain how a liquid mixture can be separat ed into lighter and heavier components by distillation, and be able to describe the basic operation of single-batch distillation systems, successive-batch dist illation systems, and continuous distillat ion syst ems. Duration: 2 hrs Objectives: Principles of Distillation Explain how changes in t emperature and pressure affect the boiling point of a substance. Define distillation. Explain how changes in t he state of matter relate t o the dist illation process. Define: sensible heat, initial boiling point , boiling range, final boiling point, and latent heat . Define: vapor pressure, ext ernal pressure, partial pressure, and relat ive volatilit y. Explain the relationship bet ween vapor pressure and the following: boiling point, temperature, and external pressure. Distillation Processes Explain how a liquid mixture can be separated int o light er and heavier components by distillation. Describe the characteristics of liquid mixtures that make distillat ion possible. Describe the basic operation of single-batch, successive-batch, and continuous distillation systems.
Subjects: Principles of Distillation States of Matter Heat Pressure Distillation Processes Separation of Liquid Mixtures Batch Continuous Course 15 of 245
Process Operations
DISTILLATION: Basic System Components and Operation (IHRDC_OM_AODBS)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic components and operation of a typical distillation system. Aft er completing t he unit , trainees should be able to describe the functions of the major components of a distillat ion system and describe how the distillation process occurs in a distillation tower. They should also be able to explain how refluxing and reboiling affect product purity and how bubble caps and packing affect t he distillat ion process in distillation towers. In addit ion, trainees should be able t o explain why it is important to monitor and cont rol distillation tower temperatures and pressures. Duration: 2 hrs Objectives: Basic Distillation System List and explain major equipment functions in a typical distillation system. Define overhead product , bot toms product, and boil-up. Describe the basic operation of a dist illation tower. Explain how a typical sieve-type distillat ion tower operates. List and explain the purpose of t he three sections of a distillation t ower. Define fractionat ion. Explain how refluxing and reboiling help minimize overlap. Define ext ernal reflux and int ernal reflux. Explain how packed t owers differ from distillation towers using bubble caps. Compare and contrast the operation of bubble caps and packing grids. Temperature and Pressure Describe adjustments made when product purity is unacceptable. Ident ify critical temperature point s in a distillat ion tower. Describe the effects of incorrect t emperatures at various points in a distillation tower. Explain what a t emperature gradient is and how it is measured. Explain how temperatures can be controlled in a basic system. Ident ify critical pressure points in a basic system. Describe the effects of incorrect pressures in a system.
Subjects: Basic Distillation System Introduction t o Dist illation Systems Tower Operat ion Refluxing and Reboiling Bubble Caps and Packing Temperature and Pressure Temperature Pressure Course 16 of 245
Process Operations
DISTILLATION: Control Systems (IHRDC_OM_AODCS)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic principles of operation of syst ems t hat control distillation processes. After completing this unit , trainees should be able to describe typical material balance and energy balance control loops and explain how these cont rol loops respond to process disturbances. They should also be able to describe how a distillation t ower is operated to maintain product specifications. Duration: 2 hrs Objectives: Balances Explain what is meant by material balance and identify typical variables. Explain what is meant by energy balance and ident ify typical variables. Describe typical material balance and energy balance control loops. Define st eady state operation and process disturbance. Describe how a typical distillat ion tower cont rol system responds to a process dist urbance (change in feed composition). Process Temperatures Describe how a typical distillat ion tower cont rol system responds to an increase in bott om t emperature. Explain how the following conditions affect the composition of a distillation system's overhead and bott om products: increase in bott om t emperature, decrease in bottom temperat ure, and change in external reflux. Product Composition Explain the difference between direct and indirect composition measurements. Explain what is meant by product giveaway. Describe how a typical distillat ion tower is operat ed to maintain product specificat ions. Explain what is meant by process lag.
Subjects: Balances Material Balance Energy Balance Process Disturbances Process Temperatures Bottom Temperat ure External Reflux Product Composition Product Specifications Maintaining Specifications Course 17 of 245
Process Operations
DISTILLATION: Operating Problems (IHRDC_OM_AODOP)
Overview: This interactive training unit is designed to familiarize trainees wit h some of the problems that can occur during the operation of distillation systems. After completing this unit, trainees should be able to describe problems that can occur when the amount of reflux going back t o the column is incorrect, and when the reboiler in a distillation system is operated improperly. Duration: 2 hrs Objectives: Feed Problems Explain the role of the feed rat e in maintaining column equilibrium. Ident ify problems t hat can occur when the feed rat e is incorrect. Describe conditions that can lead to three operating problems: overloading, flooding, and puking. Describe some mechanical causes of overloading. Explain how to identify a flooded condition in a distillation tower. Explain how a liquid flood can be broken. Explain how flooding can be prevented or controlled. Ident ify process disturbances that can result from changes in the feed to a distillat ion tower. Ident ify problems t hat can show up during startup. Reflux Problems Define reflux. Describe what can happen if the amount of reflux going back t o the column is not correct. Ident ify typical disturbances that can occur in shell and tube condensers and fin-fan condensers. Reboiler Problems Describe sources of heat input for a distillat ion tower. Explain the role of reboiler operation in maintaining column equilibrium. Ident ify problems t hat can occur when the reboiler is operated incorrectly. Ident ify typical disturbances that can occur in shell and tube reboilers and fired reboilers. Define overfract ionation.
Subjects: Feed Problems Feed Control Overloading Other Problems Reflux Problems Improper Reflux Condenser Problems Reboiler Problems Reboiler Purpose Improper Operation Overfractionation Course 18 of 245
Process Operations
DISTILLATION: System Startup and Shutdown (IHRDC_OM_AODSS)
Overview: This interactive training unit is designed to familiarize trainees wit h basic procedures for starting up and shutting down a distillation system. After completing this unit, trainees should be able to describe pre-startup checks that are commonly made on a vacuum distillat ion syst em and describe what takes place during a typical start up procedure. They should also be able to describe general procedures for short-term, emergency, and long-t erm shutdowns. Duration: 2 hrs Objectives: Startup Briefly describe the dist illation process. State the purpose of pre-startup checks. List pre-startup checks commonly made on a vacuum distillation system. Describe what takes place during a distillation startup procedure. Shutdown Describe a typical short -t erm shutdown procedure. Describe a typical emergency shutdown procedure. Describe a typical long-term shutdown procedure.
Subjects: Startup System Overview Pre-Start up Checks Startup Procedures Shutdown Short-Term Shutdown Long-Term Shutdown Course 19 of 245
Process Operations
DISTILLATION: Towers, Reboilers and Condensers (IHRDC_OM_AODTR)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic principles of operation of dist illation towers, reboilers, and condensers. After complet ing this unit, trainees should be able to describe t he difference between a binary tower and a multidraw tower and explain why the physical dimensions of a tower can vary. They should also be able to explain why vacuum dist illation and azeotropic distillation are used, and how various t ypes of reboilers and condensers are used in distillation systems. Duration: 2 hrs Objectives: Towers and Processes Describe the major difference between a binary tower and a multidraw tower. Describe the basic operation of a side-draw t ower. Describe three factors that affect the physical dimensions of a distillation tower. Given the name of a dist illation tower, describe the t ower's main function. Give three basic reasons why vacuum distillation is used. Explain what an azeot ropic mixture is and identify t wo met hods of azeotropic distillation. Reboilers and Condensers Explain the difference between the following types of reboilers: forced versus natural circulat ion and external versus internal. Describe two ways that condensers can be categorized in overhead systems.
Subjects: Towers and Processes Multidraw Towers Tower Variations Vacuum Towers Azeotropic Distillat ion Reboilers and Condensers Reboilers Condensers Course 20 of 245
Process Operations
ELECTRICAL EQUIPMENT: AC and DC Motors (IHRDC_OM_AOEAC)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with the operation of electric motors. After completing this unit , trainees should be able to explain the basic principles of motor operation and describe the basic operation of a simple AC motor and a simple DC mot or. They should also be able t o identify and describe the function of each part of a typical AC motor and a t ypical DC motor. Duration: 2 hrs Objectives: Motor Fundamentals Explain the purpose of a mot or. Explain what is meant by motor act ion. Explain the basic principles of motor operation. Define t he following terms: alternating current, rotor, and stator. Describe how a simple AC motor operates. Describe how a simple DC motor operates. Motor Parts Ident ify the parts of a typical AC motor and describe the function of each part. Ident ify the parts of a typical DC motor and describe the function of each part .
Subjects: Motor Fundamentals Basic Motor Theory AC Motor Fundamentals DC Mot or Fundamentals Motor Parts AC Motors DC Mot ors Course 21 of 245
Process Operations
ELECTRICAL EQUIPMENT: Electrical Production and Distribution (IHRDC_OM_AOEEP)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with the production and distribution of electric power for use by process syst ems. After completing this unit, t rainees should be able to identify and explain t he funct ions of the major components in an electrical distribution system. In addit ion, trainees should be able t o describe general hazards associated with these systems and how to minimize t he possible effects of the hazards. Duration: 2 hrs Objectives: Power Generation In general terms, explain how power comes int o an industrial facility from an off-site source. List three sources of on-site power generation. Power Distribution Ident ify and explain the function of the major components in a t ypical elect rical power distribution system. Ident ify general hazards associated with electrical distribution systems. Describe, in general t erms, how to aid a victim of elect rical shock. Describe, in general t erms, how to extinguish an electrical fire.
Subjects: Power Generation Off-Site Power Generation On-Site Power Generation Power Distribution System Components Safety Course 22 of 245
Process Operations
ELECTRICAL EQUIPMENT: Motor Controllers and Operation (IHRDC_OM_AOEMC)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with what mot or controllers do and how they do it. Typical steps for st arting up, checking, and shutting down motors are also covered. After complet ing this unit, trainees should be able t o explain how mot or controllers control and protect motors. They should also be able to describe how to start up a motor, perform operat ing checks on a motor, and shut down a motor. Duration: 2 hrs Objectives: Motor Controllers Explain the purpose of a mot or controller. Describe the features of a t ypical AC motor cont roller contactor. Describe how a motor controller can protect a motor. Using an electrical diagram, identify t he parts of a typical AC motor controller and describe the function of each part . State the purpose of overload devices. Explain the difference between thermal and magnetic overload devices. Ident ify the parts of typical overload devices and describe their operation. Motor Operation List typical st eps for starting up a motor. Describe normal operating checks associated with motor operation. List typical st eps for shutting down a motor.
Subjects: Motor Controllers Fundamentals AC Controllers Overload Devices Motor Operation Startup Operations Switches Course 23 of 245
Process Operations
ELECTRICAL EQUIPMENT: Transformers, Breakers and Switches (IHRDC_OM_AOEBS)
Overview: This interactive training unit is designed to familiarize trainees wit h the operation of transformers, circuit breakers, and various t ypes of switches. After completing this unit , trainees should be able to explain the principles of transformer operat ion, ident ify some of the basic components of a transformer, and describe checks that are generally made during a transformer inspection. They should also be able t o describe the general operation of a circuit breaker, explain how to reset a tripped circuit breaker and rack out a circuit breaker, and describe the basic operation of pushbotton switches and rotary switches. Duration: 2 hrs Objectives: Transformers Explain the function of a transformer. Describe, in general t erms, how a transformer works. Ident ify and describe some of the basic components of transformers. Describe checks that should be made when a transformer is inspected. Breakers and Switches Describe the general operation of a circuit breaker. List general steps associat ed with resett ing a circuit breaker that has tripped. List general steps associat ed with racking out a circuit breaker. Describe the general function of a switch. Explain how different types of pushbotton switches and rotary switches operate.
Subjects: Transformers Operating Principles Transformer Components Transformer Inspection Breakers and Switches Circuit Breaker Operat ion Reset ting and Racking Out Switches Course 24 of 245
Process Operations
EQUIPMENT DRIVE COMPONENTS: Couplings (IHRDC_OM_AOEBP)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with the general operation of equipment drive components, in particular, couplings and clutches. After completing this unit, trainees should be able to describe the general function of equipment drive components and some general operator checks and safet y concerns related t o equipment drive components. They should also be able to identify and describe various types of couplings and a typical clutch, as well as describe common operator checks and concerns that apply to these part icular equipment drive components. Duration: 2 hrs Objectives: Introduction Explain what equipment drive components are and st at e some of their functions. Describe general operator checks and safety concerns related to drive components. Explain why different types of drive components may be used t ogether in some instances. Describe basic operating characteristics that affect the operation of rotating equipment and define t he following terms: endplay, torque, torque surge, and shock load. Couplings Explain what a coupling is and describe its general function. Ident ify and describe some commonly used fixed speed couplings. Describe common operat or checks and concerns that apply t o fixed speed couplings. Explain what a variable speed coupling is, and describe it s general function. Define slip. Ident ify and describe some commonly used variable speed couplings. Describe common operat or checks and concerns that apply t o variable speed couplings. Clutches Explain what a clutch is, and its general function. Describe one type of disc clutch. Describe some general operator checks and concerns that apply to a typical clutch.
Subjects: Introduction Drive Components Charact eristics Couplings Fixed Speed Couplings Variable Speed Couplings Clutches Clutch Fundamentals Operator Checks Course 25 of 245
Process Operations
EQUIPMENT DRIVE COMPONENTS: Gear, Belt and Chain Drives (IHRDC_OM_AOEGB)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with the operation of gear drives, belt drives, and chain drives. After completing this unit, trainees should be able to describe the general function of gear drives, belt drives, and chain drives, and explain how each of these equipment drive component s operates to transfer power from a driver t o a piece of driven equipment. They should also be able to describe operator checks that are commonly performed on gear drives, belt drives, and chain drives. Duration: 2 hrs Objectives: Gears Explain what a gear drive is, and its general function. Ident ify the major component s of a typical gearbox. Describe typical operator checks and concerns that apply to gear drives. Belts and Chains Explain what a belt is and describe its general function. Describe typical single and multiple V-belt drives. Explain what a chain drive is and its general function. Describe a typical chain drive and some common ways t hat chain drives are lubricated. Describe typical operator checks and concerns that apply to belt drives. Describe typical operator checks and concerns that apply to chain drives.
Subjects: Gears Function Operator Checks Belts and Chains Belt Drives Chain Drives Operator Checks Course 26 of 245
Process Operations
EQUIPMENT LUBRICATION: Lubricants and Bearings (IHRDC_OM_AOELB)
Overview: This interactive training unit is designed to familiarize trainees wit h the types of lubricant s and bearings used in indust rial facilities. After completing this unit, trainees should be able to explain how lubricants reduce friction, describe the characteristics of oil and grease, and describe applicat ions in which oils and greases are used as lubricants. Trainees should also be able to name several solid lubricant s, and give an example of a synthetic lubricant. In addition, trainees should be able to describe sleeve bearings, rolling element bearings, and radial loads and thrust loads on shafts and bearings. Duration: 2 hrs Objectives: Oils and Greases Define friction and explain how lubricants reduce it. Define viscosit y and describe the effect of temperature on it. Define oil and explain when it is a bett er lubricant than grease. Define grease and describe its consist ency and how it is indicat ed. Describe when grease is a better lubricant than oil. Solids, Additives, and Synthetics List three solid lubricants. Explain how extreme-pressure lubricants protect gears. Explain why lubricant oxidation is harmful. Name two harmful substances formed from lubricant oxidation. State a function of detergents and dispersants in lubricants. Name a synthetic lubricant. Bearings Describe lubricant action in sleeve bearings. Describe how rolling element s help reduce frict ion. Describe thrust loads and radial loads on shafts and bearings.
Subjects: Oils and Greases Friction Oil Grease Solids, Additives, and Synthetics Solid Lubricants Additives and Synthetics Bearings Sleeve Bearings Rolling Element Bearings Course 27 of 245
Process Operations
EQUIPMENT LUBRICATION: Using Lubricants (IHRDC_OM_AOEUL)
Overview: This interactive training unit is designed to familiarize trainees wit h some of the methods and devices used t o lubricate equipment components such as bearings. Aft er completing t his unit, trainees should be able t o describe the use of hand grease guns, pneumatic grease guns, grease cups, and centralized lubricators. They should also be able to explain the basic operation of drip-feed oilers, oil baths, bottle oilers, ring oilers, and circulating oil systems. In addit ion, trainees should be able t o describe the use of cont act seals, labyrinth seals, and mechanical seals, and to describe how valve packing is lubricated. Duration: 2 hrs Objectives: Lubricating with Grease Describe two ways in which hand grease guns can be filled. Explain why bearing housings should be checked for overheating before greasing. Describe how to grease a bearing with a drain hole. Describe a pneumatic grease gun. Name two types of automat ic grease lubricators. Lubricating with Oil List four items on a typical lubrication schedule or chart. Name two ways that oil is dispensed from large drums. Describe the operation of a drip-feed oiler. Explain how an oil bath lubricates bearings and gears. Name three ways to check oil level. Explain how a bottle oiler maintains constant oil level. Explain how a ring oiler works. Describe a typical circulating oil syst em. List three things to check in a circulating oil system. Seals and Packing State two reasons for using seals. Define: contact seals, labyrint h seals, and mechanical seals. Explain why a noticeable amount of leakage from a seal can be harmful. Explain how valve packing prevents leakage. Explain why grease guns and lubricat ors are used on valves.
Subjects: Lubricating with Grease Grease Guns Automat ic Grease Lubricators Lubricating with Oil Lubrication Schedules Lubricating Devices Circulating Oil Systems Seals and Packing Seals Packing Lubrication Course 28 of 245
Process Operations
FURNACES: Introduction (IHRDC_OM_AOFIN)
Overview: This interactive training unit is designed to int roduce trainees to the basic concepts associated wit h furnace operation. After completing the unit, trainees should be able to ident ify the major parts of a furnace and describe, in general terms, how a furnace produces heat. They should also be able to explain how heat transfer occurs in a furnace, and how air, combustion gases, and process fluid moves through different t ypes of furnaces. Duration: 2 hrs Objectives: Fundamentals Ident ify the major parts of a furnace. Ident ify the major furnace systems. Explain how a furnace produces heat. Combustion State the requirements for combust ion. Ident ify three types of heat t ransfer and how they occur in a furnace. Furnace Flow Paths Define draft. Describe the basic operating principles of natural draft furnaces, forced draft furnaces, and balanced draft furnaces. Explain how draft is controlled in a natural draft furnace. Explain how process fluid circulates in a furnace. Ident ify problems associated with improper process fluid flow.
Subjects: Fundamentals Components Operation Combustion Fundamentals Heat Transfer Furnace Flow Paths Draft Process Fluid Course 29 of 245
Process Operations
FURNACES: Operating Conditions (IHRDC_OM_AOFOC)
Overview: This interactive training unit is designed to familiarize trainees wit h general operat or responsibilities associated with operating a furnace. After completing this unit, trainees should be able to identify instrumentation used to monitor furnace temperature cont rol systems and process fluid control systems. They should also be able to identify conditions t hat should be checked during furnace operations, and explain how to detect and respond to abnormal condit ions. Duration: 2 hrs Objectives: Instrumentation and Control Ident ify the instrumentation used to monitor furnace operating conditions. Describe the basic operating principles of furnace temperature control systems and process fluid control systems. Inspection and Adjustments Ident ify conditions that should be inspected during furnace operation. Explain how to detect burner problems and make the appropriate burner adjustments. Abnormal Conditions Explain how to detect and respond to these furnace air flow problems: air leaks, insufficient air flow, and afterburning. Explain how to operate a furnace at reduced firing rates. Explain how to detect and respond to freeze-ups in the fuel supply system and process fluid system.
Subjects: Instrumentation and Control Instrument at ion and Process Variables Control Syst ems Inspection and Adjustments Furnace Inspect ion Burner Adjust ment s Abnormal Conditions Air Flow Problems Fuel System Problems Process Fluid Problems Course 30 of 245
Process Operations
FURNACES: Startup and Shutdown (IHRDC_OM_AOFSS)
Overview: This interactive training unit is designed to familiarize trainees wit h basic procedures for starting up and shutting down a furnace. After completing this unit, trainees should be able to describe basic procedures for preparing a furnace for startup, establishing the flow of process fluid, and lighting the burners. They should also be able to describe general considerat ions and basic procedures associated with planned furnace shutdowns and unplanned, or emergency, furnace shutdowns. Duration: 2 hrs Objectives: Startup Describe the major operator responsibilities involved in preparing furnace startup. Explain how and why a furnace is purged. Describe how to establish the flow of process fluid in a furnace. Describe how to light gas burners, oil burners, and combinat ion burners. Describe a typical startup procedure for natural draft and balanced draft furnaces. Shutdown Describe a typical planned shutdown procedure. Ident ify furnace conditions that may require an emergency, or unplanned shutdown. Ident ify typical emergency shutdown systems and equipment.
Subjects: Startup Preparations Establishing Flow Lighting Burners Shutdown Planned Shut down Emergency Shut down Course 31 of 245
Process Operations
HEAT EXCHANGERS: Condensers and Reboilers (IHRDC_OM_AOHCR)
Overview: This interactive training unit is designed to int roduce trainees to the basic operation of condensers and reboilers. After completing this unit, t rainees should be able to describe the function and operation of a typical condenser, basic procedures for st arting up and shutting down a condenser, and some operator checks that are typically performed during condenser operation. They should also be able to explain the operation of kettle-type and thermosiphon reboilers, and identify some operator responsibilities associated with reboiler operation. Duration: 2 hrs Objectives: Condensers Describe the function of condensers. Describe the operation of a typical condenser. Describe the st artup procedure for a t ypical condenser. Describe a general condenser shutdown procedure. Describe some checks made during the operation of a condenser. Reboilers Describe how a kettle-t ype reboiler operates. Describe how a thermosiphon reboiler operates. Describe some operator responsibilit ies associated with reboiler operation.
Subjects: Condensers Condenser Operation Condenser Start ups and Shut downs Operator Checks Reboilers Kettle-Type Reboilers Thermosiphon Reboilers Operator Responsibilities Course 32 of 245
Process Operations
HEAT EXCHANGERS: Cooling Towers (IHRDC_OM_AOHCT)
Overview: This interactive training unit is designed to int roduce trainees to the basic operation of a cooling water system and various t ypes of cooling t owers. Aft er completing t his unit, trainees should be able t o explain how cooling occurs in a cooling tower, and describe the general design and operation of natural-draft and mechanical-draft cooling towers. They should also be able t o describe general procedures for shutting down and starting up one cell of a multicell cooling tower. In addition, trainees should be able to describe operator checks that are typically performed on cooling t owers, t he effects of contaminant s on cooling water, and how chemicals can be safely added to cooling water systems. Duration: 2 hrs Objectives: Introduction Describe the operation of a basic cooling wat er system. Describe what occurs in the tower during t he cooling process. Describe the general operation of a natural-draft cooling tower and the t wo types of mechanical-draft cooling t owers: induced-draft towers and forced-draft towers. Operation Describe a typical shutdown and startup procedure for one cell of a mult icell cooling tower. Describe typical operator checks for cooling towers. Chemistry Explain what suspended and dissolved solids are and how they affect a cooling water system. Explain how problems caused by suspended and dissolved solids can be minimized. Explain what dissolved gases and micro-organisms are, how they affect cooling water systems, and how their effects can be minimized. Describe ways chemicals are added to cooling water systems. Describe precautions when working with hazardous chemicals.
Subjects: Introduction Cooling Systems Cooling Tower Design Operation Cell Shutdown and Startup Operator Checks Chemistry Cooling Wat er Contamination Chemical Addition Course 33 of 245
Process Operations
HEAT EXCHANGERS: Introduction (IHRDC_OM_AOHIN)
Overview: This interactive training unit is designed to int roduce trainees to basic principles of heat t ransfer and the component s and operating principles of shell and tube, and plate heat exchangers. After completing this unit, trainees should be able to explain what heat is, and describe three ways t hat heat transfer can occur in a heat exchanger. They should also be able to describe t he basic operation and components of a shell and t ube heat exchanger, and identify auxiliary equipment that is commonly used with heat exchangers. Finally, trainees should be able to explain how a plate heat exchanger operat es and identify its components. Duration: 2 hrs Objectives: Principles Define heat. Explain heat transfer by conduction, convection, and radiation. Explain how heat is transferred in a typical heat exchanger. Explain how various factors can affect heat transfer. Shell and Tube Describe the operation of typical shell and tube heat exchangers. Explain how heat exchangers are used as coolers and heaters. Describe the functions of the auxiliary components used with heat exchangers. Describe the different flow paths fluids take in shell and tube heat exchangers. Plate Describe the basic operation of a plate heat exchanger. Ident ify the component s of a typical plate heat exchanger.
Subjects: Principles Heat and Heat Transfer Heat Transfer Factors Shell and Tube Basic Operation Auxiliary Equipment Flow Paths Plate Operation Components Course 34 of 245
Process Operations
HEAT EXCHANGERS: Operation of Shell and Tube Types (IHRDC_OM_AOHOS)
Overview: This interactive training unit is designed to familiarize trainees wit h the startup, operation, and shut down of shell and tube heat exchangers. After completing this unit, trainees should be able to describe general procedures for the startup and shutdown of a shell and tube heat exchanger and ident ify some of the operator responsibilit ies associated with their operation. Trainees should also be able to identify basic operating problems that may be associated with shell and tube heat exchangers, and explain how they can be corrected. Duration: 2 hrs Objectives: Startup and Shutdown Describe a general procedure for starting up a shell and tube heat exchanger. Describe a general procedure for shutting down a shell and tube heat exchanger. Describe general operator responsibilities associated with the operation of a shell and tube heat exchanger. Heat Exchanger Problems Explain what fouling is and how it can be correct ed. Explain what leakage is and how it can be correct ed. Explain what air or vapor binding is and how it can be corrected.
Subjects: Startup and Shutdown Startup Shutdown Operator Responsibilities Heat Exchanger Problems Fouling Tube Leaks Air and Vapor Binding Course 35 of 245
Process Operations
I & C: Automatic Process Control 1 (IHRDC_OM_AOIA1)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with automatic control of process systems. Aft er completing t his unit, trainees should be able t o describe the functions of t he four basic element s of an automatic process control system and explain how a process dist urbance can affect a process control system. They should also be able to explain how feedback control and feedforward control can be used in process control systems. In addition, trainees should be able to explain how resistance, capacit ance, dead time, and lag time can affect a process cont rol system. Duration: 2 hrs Objectives: Control Methods State the function of a process control system. Describe the functions of the four basic elements of an automated process control system. Explain what a process disturbance is and how it can affect a process control syst em. Describe feedback and feedforward cont rol and explain how they can be used in a process control system. Process Dynamics Define resist ance and capacit ance. Define dead time and lag time. Explain how resistance, capacitance, dead t ime, and lag t ime can affect a process control syst em.
Subjects: Control Methods Automat ic Control Syst ems Feedback Control Feedforward Control Process Dynamics Process Charact eristics System Responses Course 36 of 245
Process Operations
I & C: Automatic Process Control 2 (IHRDC_OM_AOIA2)
Overview: This interactive training unit is designed to familiarize trainees wit h control modes used with automatic process control syst ems. Aft er completing t his unit, trainees should be able t o describe two-position control, proport ional cont rol, reset control, rate cont rol, and PID control and explain how each of these control modes works in a control system. They should also be able to explain how proport ional band applies to a control system. Duration: 2 hrs Objectives: Two-Position and Proportional Describe two-position control and explain how it works in a control system. Describe proportional control and explain how it works in a control system. Explain how proportional band applies to a control system. Reset, Rate, and PID Describe reset control and explain how it works in a control system. Describe rate cont rol and explain how it works in a control system. Describe PID control and explain how it works in a control system.
Subjects: Two-Position and Proportional Two-Position Cont rol Proportional Control Proportional Band Reset, Rate, and PID Reset Control Rate Control PID Control Course 37 of 245
Process Operations
I & C: Measurement of Concentration (IHRDC_OM_AOIMC)
Overview: This interactive training unit is designed to int roduce trainees to some informat ion about analytical variables and to some methods for measuring concentration in liquids and gases. After complet ing this unit, trainees should be able to define five analytical variables that are commonly measured in plants, and explain how and why analytical variables are measured. They should also be able to describe the basic operat ion of several different types of analyzers that can be used t o measure liquid and gas concentrations. Duration: 2 hrs Objectives: Introduction to Analytical Measurement State the general purpose of analytical measurements. Define: concentration, density, clarity, humidity, moisture, and analyzer. Liquid Concentration Analysis Explain what pH measurements represent. Explain how a pH scale is structured and how t o interpret pH values. Describe the basic operation of a typical pH analyzer and a typical electrical conductivity measuring device. Gas Concentration Analysis Describe the basic operation of a paramagnetic oxygen analyzer, a thermal conductivity gas analyzer, and a chromatograph.
Subjects: Introduction to Analytical Measurement Analytical Variables Measuring Analytical Variables Liquid Concentration Analysis What is Concentration? pH Measurements pH Analyzer Operation Conductivity Measurements Gas Concentration Analysis Oxygen Concentration Measurement Non-Oxygen Gas Concentration Measurement Complex Gas Concentration Measurement Course 38 of 245
Process Operations
I & C: Measurement of Density, Clarity and Moisture (IHRDC_OM_AOIDC)
Overview: This interactive training unit is designed to int roduce trainees to some devices that can be used to measure density, clarity, and moisture. After completing this unit, trainees should be able to define various terms associated wit h density, clarity, and moisture, and describe t he basic operation of devices used to measure density, clarit y, humidity, and moist ure. Duration: 2 hrs Objectives: Density Measurement Define density. Explain the difference between density and specific gravity. Describe the basic operation of a hydrometer. Describe the use of a bubbler system to measure density. Describe the operation of a radioactive density analyzer. Clarity Measurement Define clarity. Describe the basic operation of a colorimeter, a turbidity meter, and an opacity meter. Moisture Measurement Define humidity and moisture. Describe the basic operation of a sling psychromet er. Describe the basic operation of a wet and dry bulb recording psychromet er. Describe the basic operation of a hygrometer. Describe the basic operation of an infrared moisture analyzer.
Subjects: Density Measurement Density and Specific Gravity Hydrometers Density Bubbler System Radioact ive Density Analyzer Clarity Measurement Principles of Clarity Analysis Colorimeter Turbidity Meter Opacity Meter Moisture Measurement Humidity and Moisture Measuring Humidit y Measuring Moisture Course 39 of 245
Process Operations
I & C: Measurement of Level and Flow (IHRDC_OM_AOIML)
Overview: This interactive training unit is designed to int roduce trainees to instruments that measure level and flow. After complet ing this unit, trainees should be able t o explain what level is and describe the basic operation of various direct and indirect level measurement devices. They should also be able to explain what fluid flow, flow rate, and total flow are and describe some common examples of direct and indirect flow measurements. Duration: 2 hrs Objectives: Level Measurement Define: level, cont inuous level measurement, and single-point level detection. Describe basic operation of t he following level measurement devices: plumb bob, gauge glass, float and tape, and conductivit y probes. Describe the basic operation of these level measurement devices: pressure gauge, bubbler system, and D/P cell. Flow Measurement Define fluid flow, flow rate, and total flow. List basic units of measurement for flow rate. Describe common examples of direct flow measurement. Describe common examples of indirect flow measurement.
Subjects: Level Measurement Principles of Level Measurement Direct Level Measurement Devices Indirect Level Measurement Devices Flow Measurement Principles of Flow Measurement Direct Flow Measurement Devices Indirect Flow Measurement Devices Course 40 of 245
Process Operations
I & C: Measurement of Pressure and Temperature (IHRDC_OM_AOIMP)
Overview: This interactive training unit is designed to int roduce trainees to some of the fundamental aspects of process variable measurement and to some of t he basic instruments used for pressure and temperature measurement. After completing this unit, trainees should be able t o describe the function of process instrument at ion and how t o obt ain accurate readings from instruments such as gauges, indicators, and recorders. They should also be able to explain what pressure and temperat ure are and how they are expressed, and t he operat ion of several pressure and temperature measuring devices. Duration: 2 hrs Objectives: Measuring Process Variables State the general function of process instrumentation. List four process variables monitored by process instrumentation. Explain how parallax can affect an instrument reading. Explain how to use a multiplication factor when reading an instrument. Describe how to read gauges, indicators, recorders, and digital met ers. Pressure Measurement Define pressure in t erms of solids, liquids, and gases. Describe three types of scales used to indicat e pressure. List basic units of measurement for pressure. Describe three types of manometers. Describe the basic operation of Bourdon tube, bellows, and diaphragm pressure elements. Describe the basic operation of a pressure transmitter. Temperature Measurement Explain the general relationship between heat and temperature. List basic units of measurement for temperature. Describe the basic operation of a fluid thermometer, bimetallic thermometer, thermocouple, and Resist ance Temperature Detector (RTD).
Subjects: Measuring Process Variables Process Variables and Inst rumentation Reading Instruments Pressure Measurement Pressure and Pressure Scales Manometers Pressure Elements and Transmitt ers Temperature Measurement Temperature and Temperature Scales Thermometers Thermocouples and RTDs Measurement of Level and Flow Course 41 of 245
Process Operations
INDUSTRIAL MATH: Algebra (IHRDC_OM_AOIAL)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic concepts of algebra. Aft er completing t his unit, t rainees should be able to define t erms commonly associated with the use of algebra, isolate an unknown in an equat ion, and use t he processes of distribution and factoring. They should also be able to explain what ratios and proportions are, and the difference between a direct proport ion and an inverse proportion. Finally, trainees should be able to use a calculator to solve math problems. Duration: 2 hrs Objectives: Introduction to Algebra State the difference between arithmetic and algebraic operations. Define t he terms: constant, unknown, variable, and equation. Describe how equations are used to solve an arithmetic or algebraic problem. Explain how to maintain an equation's balance. Describe how the unknown in an equat ion can be isolated. Describe the operation of dist ribut ion. Describe the operation of fact oring. Ratios and Proportions Explain what a ratio is and how ratios can be expressed. Explain the difference between a direct proport ion and an inverse proportion. Calculators Explain how to use a calculator.
Subjects: Introduction to Algebra Basic Principles Isolating an Unknown Distribution Factoring Ratios and Proportions Calculators Parts of a Calculator Types of Logic Course 42 of 245
Process Operations
INDUSTRIAL MATH: Basic Operation 1 (IHRDC_OM_AOIB1)
Overview: This interactive training unit is designed to int roduce trainees to the basic principles of addition, subt raction, multiplication, and division. After completing this unit, t rainees should be able to describe how to add, subt ract, and multiply numbers in vertical columns, and how to do short and long division. They should also be able t o explain powers of numbers and roots of numbers, as well as shortcuts for multiplying and dividing with multiples of ten. Duration: 2 hrs Objectives: Addition and Subtraction Define number line. Describe the basic principles of addition and subtract ion. Describe the base 10 number system. Describe how to add and subtract numbers in vertical columns. Multiplication Describe the basic principles of mult iplicat ion. Explain how to use a multiplication table. Describe how to multiply numbers in vertical columns. Describe a shortcut for multiplying with multiples of t en. Explain powers of numbers. Explain root s of numbers. Division Describe the basic principles of division. Explain how short division is done. Explain how long division is done. Describe a shortcut for dividing with multiples of ten. Describe a shortcut for dividing with powers of numbers.
Subjects: Addition and Subtraction Number Line Addition in Vertical Columns Subtraction in Vertical Columns Multiplication Principles of Multiplication Multiplication in Vertical Columns Powers and Roots Division Principles of Division Long Division Course 43 of 245
Process Operations
INDUSTRIAL MATH: Basic Operation 2 (IHRDC_OM_AOIB2)
Overview: This interactive training unit is designed to familiarize trainees wit h basic mathematical operations involving signed numbers, averaging, rates, fract ions, decimals, and conversions. After completing this unit, trainees should be able to perform basic mathematical operations with signed numbers, perform combined operations in the proper order, find the average of a group of numbers, and calculate rates. They should also be able to add, subtract , multiply, and divide with fract ions and decimals. Finally, t rainees should be able to convert between fract ions, decimals, and percents; write numbers using scientific notation; and use conversion tables. Duration: 2 hrs Objectives: Math Operations Explain how to do basic math operat ions with signed numbers. Define grouping symbols. Explain the order in which combined operations are performed. Explain how to calculate averages and rates. Fractions Explain what a fraction is, and how t o add and subtract them. Describe how to get common denominators, and what a lowest common denominator is. Explain how to multiply and divide fractions. Explain how to express a fraction in simplest terms. Explain what a mixed number is, and how to convert whole and mixed numbers to fractions. Decimals and Conversions Define decimal. Describe basic math operat ions involving decimals. Describe how to convert between fractions and decimals. Describe how to write numbers using scientific notation. Explain what percents are. List how to convert between fractions, decimals, and percents. Describe conversion tables: factor-type and equivalents-type.
Subjects: Math Operations Signed Numbers Combined Operat ions Averaging Rates Fractions Add and Subtract Multiply and Divide Mixed Numbers Decimals and Conversions Decimals Number Conversions Conversion Tables Course 44 of 245
Process Operations
INDUSTRIAL MATH: Formulas, Graphs and Trends (IHRDC_OM_AOIFC)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic principles associated with using formulas, reading and interpreting graphs, and detecting and analyzing trends. After completing this unit, t rainees should be able to explain what a formula is and how to use formulas to find areas, volumes, and volumetric flow rates. They should also be able t o describe how graphs and charts can provide information about process variables. In addition, trainees should be able to describe basic procedures for det ecting and analyzing trends. Duration: 2 hrs Objectives: Formulas Define formula. Describe how formulas can be used to find areas. Describe how formulas can be used to find volumes. Define flow rate. Describe how to use volumetric flow rate formulas. Graphs, Charts, and Trends Describe how graphs can provide information about process variables. Describe how charts can provide information about process variables. Describe what a t rend is and explain t he difference between expected trends and unexpected trends. Describe some basic procedures for detecting a trend. Describe some basic procedures for analyzing a trend.
Subjects: Formulas Area Volume Volumetric Flow Rate Graphs, Charts, and Trends Graphs Charts Trends Course 45 of 245
Process Operations
ON-THE-JOB-TRAINING: Implementation and Evaluation (IHRDC_OM_AOOIE)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with on-the-job training (OJT) of plant operators. After completing this unit, trainees should be able to identify qualities that an effective OJT instructor should possess, and describe considerations associat ed with scheduling, planning for, and conduct ing OJT. They should also be able to describe how t he trainee, the instructor, and the overall OJT program can be evaluated. Duration: 2 hrs Objectives: Implementation Ident ify qualities and characteristics of an effective OJT inst ructor. Ident ify some t raining strategies t hat an instructor can use during OJT. Describe considerations involved in scheduling OJT. Ident ify preparations that should be made before OJT is implemented. Describe met hods of conducting OJT. Describe coaching skills that an instructor can use during OJT. Evaluation Describe how a trainee's performance can be evaluat ed. Describe how on-the-job training instructors can evaluate themselves and the OJT program. Review the main steps and principles of a typical OJT program.
Subjects: Implementation The OJT Instructor Planning for OJT OJT Methods Evaluation Trainee Evaluation Program Evaluation OJT Review Course 46 of 245
Process Operations
ON-THE-JOB-TRAINING: Preparation (IHRDC_OM_AOOPR)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with on-the-job training (OJT) of plant operators. After completing this unit, trainees should be able to compare OJT and classroom training, and describe the basic steps in a formalized OJT program. They should also be able to explain how to determine specific training needs for a t rainee, and describe training materials that are commonly used for OJT. Duration: 2 hrs Objectives: What is OJT? Compare OJT and classroom training. List advantages and disadvantages of OJT. Ident ify the basic steps included in a formal OJT program. Training Needs Ident ify sources of information for analyzing an operator's job. Explain what a job and task analysis is. Describe how to profile the trainee and tailor training according to individual needs. Describe how to determine training needs t hat are to be met specifically through OJT. Training Materials Explain what a performance object ive is. Describe the use of an OJT t raining checklist. Ident ify some t raining aids that can be used for OJT.
Subjects: What is OJT? OJT vs. Classroom Training Pros and Cons Basic Steps Training Needs Job and Task Analysis Trainee Profile Determining Training Methods Training Materials Object ives and Checklists Training Aids Course 47 of 245
Process Operations
OPERATOR RESPONSIBILITIES: Communication (IHRDC_OM_AOOCO)
Overview: This interactive training unit is designed to familiarize trainees wit h basic operator responsibilities associated with int erpersonal relationships and data collection and use. After complet ing this unit, trainees should be able to describe t he components of a basic communication model and an operator's responsibilit ies for communicating with other plant personnel, customers, and members of the surrounding communit y. They should also be able to describe operator responsibilities associated with collecting and using written data and participating in effective shift changes. Duration: 2 hrs Objectives: Interpersonal Responsibilities Describe the components of a basic communicat ion model. Describe basic operator interpersonal responsibilities with the company, peers, supervisory personnel, personnel in other departments, and new operators. Ident ify the four steps in an on-the-job training program for new operators. Describe basic operator interpersonal responsibilities with customers and the communit y. Data Collection and Use Describe operator responsibilities associat ed with scheduled readings, statist ical process control (SPC) charts, sample and laboratory analysis reports and logs. Ident ify three characteristics of an effective relief.
Subjects: Interpersonal Responsibilities The Communication Model Inside the Plant Out side the Plant Data Collection and Use Writt en Dat a Oral Dat a Course 48 of 245
Process Operations
OPERATOR RESPONSIBILITIES: Introduction (IHRDC_OM_AOOTC)
Overview: This interactive training unit is designed to familiarize trainees wit h the general responsibilities of an operat or in an indust rial facility. After completing this unit, t rainees should be able to describe operator responsibilities associat ed with process cont rol, safety, and communication. They should also be able to describe an outside operator's responsibilities during inspections and routine operations, and t he general responsibilities of a cont rol room operat or. They should also be able t o describe the effect s t hat changing weather condit ions have on system operation. Duration: 2 hrs Objectives: Overview Describe operator responsibilities associat ed with controlling a product ion process, safe operation of a facility, and fire and accident prevention. Explain why good communications are important in an industrial facility. Ident ify the types of information t hat an oncoming operator should find out during a shift change. Plant Operators Describe an outside operat or's responsibilities during inspections. Describe an outside operat or's responsibilities during routine operat ions. Describe the general responsibilities of a control room operator. Describe the effects of changing weather conditions on system operat ion.
Subjects: Overview The Operator's Role Plant Operators Out side Operators Control Room Operat ors Course 49 of 245
Process Operations
OPERATOR RESPONSIBILITIES: Plant Production and Safety (IHRDC_OM_AOOPP)
Overview: This interactive training unit is designed to familiarize trainees wit h operator responsibilities during routine plant production operations and for ensuring safety during all phases of plant operation. After completing this unit, t rainees should be able to describe operator responsibilities associated wit h routine production dut ies, prevent ive maintenance, and troubleshooting. They should also be able t o describe operat or safety responsibilities for normal and abnormal operations and during scheduled st artups and shutdowns. In addition, t hey should be able to describe the operator's role with respect to permit procedures and government regulations. Duration: 2 hrs Objectives: Production Describe operator responsibilities associat ed with routine product ion duties, data interpretation, waste disposal, and vapor emissions monit oring. Describe operator responsibilities associat ed with prevent ive maintenance. Describe operator responsibilities associat ed with troubleshoot ing. Safety Describe operator safety responsibilit ies associated with normal plant conditions. Describe operator safety responsibilit ies associated with abnormal plant conditions. Describe operator safety responsibilit ies associated with scheduled plant st artups and shutdowns. Describe the operator's role in lockout/tagout procedures and confined space procedures. Explain, in simple t erms, the purposes of t he following regulations: HAZCOM, HAZWOPER, and SARA III.
Subjects: Production Operator Duties Prevent ive Maintenance and Troubleshooting Safety Normal and Abnormal Conditions Startups and Shutdowns Permit s and Regulat ions Course 50 of 245
Process Operations
OPERATOR RESPONSIBILITIES: Trends, Maintenance and Emergencies (IHRDC_OM_AOOIM)
Overview: This interactive training unit is designed to familiarize trainees wit h basic operator responsibilities associated with trend analysis, equipment maintenance, and emergency situat ions. After completing this unit, trainees should be able to describe ways to detect and analyze trends, explain how work orders are used, and describe how to perform some minor maintenance tasks. They should also be able t o explain how operators can prepare for emergency sit uations and describe operator responsibilities during emergencies. Duration: 2 hrs Objectives: Trends Describe how trends can be detect ed. Describe a four-step approach to analyzing trends. Maintaining Equipment Explain the purpose of work orders. Describe how valve packing can be adjusted. Describe how to safely reset a t ripped circuit breaker. Describe how to change a strainer basket in a duplex strainer. Emergency Situations Explain how operat ors can prepare for emergency situat ions. Describe general operator responsibilities during emergency situations. Describe general operator responsibilities during fire emergency situations.
Subjects: Trends Trend Detection Trend Analysis Maintaining Equipment Work Orders Operator Tasks Emergency Situations Preparing for Emergencies Responding t o Emergencies Course 51 of 245
Process Operations
PIPING AND AUXILIARIES: Basic Components and Functions (IHRDC_OM_AOPAB)
Overview: This interactive training unit is designed to familiarize trainees wit h some of the basic components commonly found in piping systems. Aft er completing t his unit, trainees should be able t o state t he purpose of piping and pipe fittings, and be able to list some common types of pipe fittings. They should also be able to describe devices t hat are used to accommodat e the weight and movement of piping, and to explain how insulation and heat tracing help t o control temperatures in piping systems. Duration: 2 hrs Objectives: Pipes and Pipe Fittings State the purpose of piping. State the purpose of pipe fittings. Describe the following types of pipe fitt ings: nipple, coupling, union, flange, elbow, t ee, Y, bell reducer, bushing, plug, and cap. Pipe Weight and Movement Explain why piping moves and why this movement needs to be controlled. State the functions of pipe hangers and supports. State the functions of expansion joints and expansion loops. Insulation and Heat Tracing Explain why piping is insulat ed. Describe how steam and electrical heat tracing met hods work.
Subjects: Pipes and Pipe Fittings Pipes and Connections Types of Pipe Fit tings Pipe Weight and Movement Pipe Supports Expansion Devices Insulation and Heat Tracing Insulation Heat Tracing Course 52 of 245
Process Operations
PIPING AND AUXILIARIES: System Components and Operation (IHRDC_OM_AOPAS)
Overview: This interactive training unit is designed to familiarize trainees wit h some of the auxiliary components commonly found in piping systems. Aft er completing t his unit, trainees should be able t o describe the function and operation of rupture discs, relief valves, safety valves, and some common t ypes of steam traps. They should also be able to describe basic procedures for draining liquid systems and some typical operator checks for fluid systems. Duration: 2 hrs Objectives: Protective Devices Describe the function and operation of a rupt ure disc. Describe the function and operation of a relief valve. Describe the function and operation of a safet y valve. Steam Traps Describe the function of a steam t rap. Describe the operation of the following t ypes of mechanical st eam traps: float traps and inverted bucket traps. Describe the operation of a thermostatic steam trap. Describe some typical operator checks for steam traps. System Operation Describe basic procedures for draining liquid systems. Describe basic procedures for filling liquid systems. Describe typical operator checks for fluid systems.
Subjects: Protective Devices Rupture Discs Relief Valves Safety Valves Steam Traps Mechanical Steam Traps Thermostatic St eam Traps Operator Checks System Operation Draining Liquid Systems Filling Liquid Systems Operator Checks Course 53 of 245
Process Operations
PLANT SCIENCE: Basic Electrical Circuits (IHRDC_OM_AOPBC)
Overview: This interactive training unit is designed to familiarize trainees wit h basic principles associated with the parts and operation of electrical circuits. Aft er completing t his unit, trainees should be able t o identify the parts of a basic circuit, describe the relationships bet ween volt age, current, and resistance in a circuit, explain how current flows through series circuits and parallel circuits, describe t he basic operation of transformers, fuses, circuit breakers, and solenoids, and explain how volt meters and ammeters can help operators detect electrical problems. Duration: 2 hrs Objectives: Basic Circuits List the parts of a basic circuit . Explain how Ohm's Law describes the relationships between current, voltage, and resistance in a circuit. Explain the basic difference between series circuits and parallel circuit s with respect to current flow. Describe the basic operation of a transformer. Explain the difference between a st ep-up transformer and a step-down transformer. Protection and Indicators State the general function of fuses and circuit breakers. Describe the basic operation of a fuse. Describe the basic operation of a circuit breaker. Describe the basic operation of a solenoid. Explain how volt meters and ammeters can help personnel spot electrical problems before equipment damage occurs.
Subjects: Basic Circuits Parts of a Circuit Ohm's Law Series and Parallel Circuits Transformers Protection and Indicators Prot ective Equipment Volt meters and Ammeters Course 54 of 245
Process Operations
PLANT SCIENCE: Basic Electrical Principles (IHRDC_OM_AOPBE)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic principles of electricity and the basic operation of electric motors. After completing this unit, trainees should be able to explain what electricity is, and how it can be produced by chemical action, heat, light, and magnetic effects. They should also be able to describe t he basic operation of a DC motor, a single-phase AC motor, and a three-phase AC mot or. Duration: 2 hrs Objectives: Electricity Define t he following terms: electrical pot ential, current, and voltage. Describe three sources of electrical pot ential: chemical act ion, heat, and light. List the three element s necessary to create an electrical potent ial using magnetic effects. Recognize and describe a sine wave. Explain the basic differences between single-phase power and three-phase power. Electric Motors Describe basic motor action. Describe the principle of operation of a DC mot or. Describe the principle of operation of an AC motor.
Subjects: Electricity What is Electricit y? Chemical Act ion, Heat, and Light Electricit y, Magnetism, and Alternating Current Electric Motors Basic Motor Operation DC Mot or Operation AC Motor Operat ion Course 55 of 245
Process Operations
PLANT SCIENCE: Basic Principles (IHRDC_OM_AOPBP)
Overview: This interactive training unit is designed to int roduce trainees to scientific principles associated with units of measurement and with force and motion. After completing this unit , trainees should be able to identify fundamental units of measurement for length, time, and mass, and identify fundamental units of measurement for pressure, temperature, flow, and level. They should also be able to explain the relationship bet ween force and motion and describe t he three laws of force and motion. Duration: 2 hrs Objectives: Unit of Measurement Ident ify fundamental units of measurement for length, time, and mass. Ident ify fundamental units of measurement for t he process variables pressure, temperature, flow, and level. Force and Motion Explain the relationship bet ween force and motion. State the t hree laws of force and motion. Define inertia. Define acceleration.
Subjects: Units of Measurement Fundamental Dimensions Process Variable Measurements Force and Motion Introduction Laws of Force and Motion Course 56 of 245
Process Operations
PLANT SCIENCE: Fluid Systems (IHRDC_OM_AOPFS)
Overview: This interactive training unit is designed to int roduce trainees to the characteristics, components, and operation of fluid systems. Aft er completing t his unit, trainees should be able t o explain, in general terms, what a plant system is, and what a fluid is. They should also be able to explain the basic layout of a liquid system and describe energy conversions in a liquid system. Trainees should also be able to describe the basic parts of a compressed air system and the basic operation of several gas and vapor system devices. Duration: 2 hrs Objectives: Liquid Systems Explain, in general t erms, what a plant system is. Explain what a fluid is. Describe the effects of pressure changes on a static fluid. Describe the four basic parts of a liquid syst em. Describe the effects of energy conversions on a fluid under steady-state conditions. Describe some of the energy conversions t hat take place in liquid syst ems. Gas and Vapor Systems Describe the basic part s of a typical compressed air system. Describe the operation of a jet pump. Describe the operation of a nozzle. Describe the operation of a condenser.
Subjects: Liquid Systems Systems and Fluids Basic System Layout Energy Conversions Gas and Vapor Systems Compressed Air System Gas and Vapor System Devices Course 57 of 245
Process Operations
PLANT SCIENCE: Forces and Machines (IHRDC_OM_AOPLM)
Overview: This interactive training unit is designed to int roduce trainees to scientific principles associated with applied forces and the operation of basic machines. Aft er completing t his unit, trainees should be able t o define work, power, and efficiency, and explain t he mechanical advantage of the inclined plane and the lever. They should also be able to explain the hydraulic principle and the relationship between friction and the operation of machines. Duration: 2 hrs Objectives: Work, Power, and Efficiency Define work and explain its relat ionship to energy. Define power. Explain why efficiency is important to plant operation. Basic Machines Define mechanical advant age. Explain the mechanical advant age of the inclined plane. Explain the mechanical advant age of the lever. Explain the hydraulic principle and give examples of where it applies. Discuss some of the effect s of friction.
Subjects: Work, Power, and Efficiency Work Power Efficiency Basic Machines The Inclined Plane The Lever The Hydraulic Principle Friction Course 58 of 245
Process Operations
PLANT SCIENCE: Gases and Flowing Liquids (IHRDC_OM_AOPGF)
Overview: This interactive training unit is designed to familiarize trainees wit h general concepts associated with the properties of gases and flowing liquids. After completing this unit , trainees should be able to describe the major properties of gases and explain how these properties are related. They should also be able to explain how pressure can be measured and the effects of flow, velocity, and friction on t he head pressure of a liquid. Duration: 2 hrs Objectives: Gas Properties Describe the effects of temperature and pressure on gases. Explain how Boyle's Law and Charles' Law relate to the pressure and volume of gases. Explain how the General Gas Law relates to temperature, pressure and volume of a gas. Measuring Pressure Explain how at mospheric pressure can be measured. Describe the effects of pressure on a manometer. Explain how various scales can be used to measure pressure. Flowing Liquids Define: flow, flow rat e, steady-state conditions, st at ic conditions, head, and head pressure. Describe the effects of flow on pressure. Describe the effects of velocity on pressure. Describe the effects of friction on pressure.
Subjects: Gas Properties Temperature and Pressure Effect s Gas Laws Measuring Pressure Atmospheric Pressure Manometers Pressure Scales Flowing Liquids Flow and Flow Rate Effects of Flowing Liquids Course 59 of 245
Process Operations
PLANT SCIENCE: Heat (IHRDC_OM_AOPHE)
Overview: This interactive training unit is designed to int roduce trainees to some of the basic principles associated with heat and heat t ransfer. After completing this unit , trainees should be able to describe some of t he effects of heat , the relationship between t emperature and thermal energy, and the Law of Energy Conservat ion. Trainees should also be able to define terms sensible heat and latent heat and to describe the effects of pressure on the t emperature at which a substance undergoes a phase change. Duration: 2 hrs Objectives: What Is Heat? Describe some of the effects of heat. Describe the relationship bet ween temperature and thermal energy. Describe the Law of Energy Conservation. Phase Changes Define sensible heat and latent heat. Describe the effects of pressure on the t emperature at which a substance undergoes a phase change.
Subjects: What is Heat? Effects of Heat Temperature and Thermal Energy The Law of Energy Conservation Phase Changes Sensible Heat and Lat ent Heat Temperature and Pressure Course 60 of 245
Process Operations
PLANT SCIENCE: Heat Transfer (IHRDC_OM_AOPHT)
Overview: This interactive training unit is designed to int roduce trainees to the fundamentals of heat transfer and the basic operation of a t ypical heat exchanger. Aft er completing t his unit, trainees should be able t o describe the effect s of a temperat ure difference on heat t ransfer and the three modes of heat transfer. They should also be able t o describe the basic operation of a shell and t ube heat exchanger and identify problems that can occur in a heat exchanger. Duration: 2 hrs Objectives: Heat Transfer Fundamentals Describe the effects of temperature difference on heat t ransfer. Define specific heat and give examples. Recognize the formula for heat transfer. Modes of Heat Transfer List and describe the three modes of heat transfer. Describe conduct ion heat transfer. Describe natural convect ion and forced convection. Describe how heat transfer takes place bet ween two fluids separat ed by a solid boundary. Describe what affects heat transfer between two fluids. Describe radiation heat transfer. Heat Exchanger Operation Describe the general operation of a shell and tube heat exchanger. Describe the operation of a lube oil cooler. Describe problems that can occur in heat exchangers and explain how these problems can be minimized. Describe the insulating effects of rust and scale buildup.
Subjects: Heat Transfer Fundamentals The Process of Heat Transfer Specific Heat Heat Transfer Formula Modes of Heat Transfer Conduction Convection Radiation Heat Exchanger Operation Shell and Tube Heat Exchangers Heat Exchanger Problems Course 61 of 245
Process Operations
PLANT SCIENCE: Process Dynamics and Measurement (IHRDC_OM_AOPPD)
Overview: This interactive training unit is designed to familiarize trainees wit h the characteristics of dynamic process operation and with devices that are commonly used to measure process variables. After complet ing this unit, trainees should be able to explain what resistance and capacitance are in process systems and to describe factors that affect the response of a process system t o operating changes and process disturbances. Trainees should also be able t o describe devices that can be used to measure pressure, flow, level, and temperature. Duration: 2 hrs Objectives: Dynamic Operation Describe resistance and capacitance in process syst ems. Describe and give examples of system characteristics between periods of steady-state conditions when changes occur. Process Variable Measurement Describe ways t hat pressure can be measured. Describe ways t hat flow can be measured. Describe ways t hat level can be measured. Describe ways t hat temperat ure can be measured.
Subjects: Dynamic Operation Resistance and Capacitance System Response to Changes Process Variable Measurement Pressure Measurement Devices Flow Measurement Devices Level Measurement Devices Temperature Measurement Devices Course 62 of 245
Process Operations
PLANT SCIENCE: Solids and Liquids (IHRDC_OM_AOPSL)
Overview: This interactive training unit is designed to familiarize trainees wit h basic scientific principles that relate to solids and liquids. Aft er completing t his unit, trainees should be able t o describe the general molecular structure of solids, liquids, and gases. They should also be able to describe specific properties attributed to solids and liquids. Duration: 2 hrs Objectives: Forms of Matter Ident ify the three forms of matter and explain how they are struct ured. Give a general description of the molecular structure and the characterist ics of solids, liquids, and gases. Compare and contrast the molecular structures of different solids. Explain why liquids can flow. Solids Define mass, density, and stress. Ident ify five types of stress and t heir effects on solids. Define elast icity and t emperature. Describe the effects of temperature on solids. Liquids Describe how liquids seek t heir own level. Define viscosit y. Describe the property of wet ting and explain why it occurs. Describe buoyancy and explain why it occurs. Describe specific gravity and how it relates t o density. Describe the effects of temperature and pressure on liquids.
Subjects: Forms of Matter Solids Mass and Density Stress and Elasticity Temperature Effects Liquids Properties of Liquids Temperature and Pressure Effect s Course 63 of 245
Process Operations
POWER PLANT BOILERS: Abnormal Conditions and Emergencies (IHRDC_OM_AOBAC)
Overview: This is an interactive training module designed to familiarize trainees wit h some abnormal operating conditions t hat a boiler operator may encounter on the job. Specific att ention is directed to typical procedures used by plant s to handle these situations and to the methods and means available to the operator to anticipate problems and to minimize the chances of t heir occurring. Duration: 2 hrs Objectives: Common Problems Describe typical procedures for dealing wit h the loss of certain boiler auxiliaries. Describe basic procedures for dealing wit h leaks that occur inside and outside a boiler. Describe how safety valves are used to protect boilers against overpressure. Describe what boiler operat ors should do to deal with leaking safety valves. Describe basic procedures for dealing wit h fires in coal yards, bunkers, feeders, pulverizers, and air preheaters. Explain how equipment fires start and identify actions that operators should avoid when equipment fires occur. Boiler Explosions Describe some of the basic causes of boiler explosions. Explain what operators can do to help prevent boiler explosions. Describe some situations that can cause a loss of all boiler flame. Describe some basic procedures for preventing a loss of all boiler flame.
Subjects: Common Problems Loss of Auxiliaries Leaks Overpressure Equipment Fires Boiler Explosions Causes of Explosions Loss of Flame Course 64 of 245
Process Operations
POWER PLANT BOILERS: Combustion and Operation (IHRDC_OM_AOBCO)
Overview: The requirements for combustion in a boiler are identified and described. This unit traces the air and gas flow path through a t ypical boiler and describes the functions of the components in the flow path. Principles of boiler operation from an operat or's point of view are identified and described. Duration: 2 hrs Objectives: Combustion List elements needed for combustion in a boiler. Describe the parts and function of a typical burner in a boiler furnace and howthe burner helps to satisfy the elements of combust ion in a boiler. Describe the fuel system for a typical coal-fired boiler. Describe a typical burner for an oil-fired boiler. Describe a typical burner for a gas-fired boiler. Define t he following terms: fuel/air ratio, excess air, and excess oxygen. Describe operator responsibilities associat ed with maintaining t he correct fuel/air ratio. Air and Gas Trace t he air and gas flow pat h through a boiler. Explain how hot combustion gases are used to increase boiler efficiency. Describe the basic operation of two t ypes of air preheaters. Describe some of the harmful effects that can be caused by combustion gas by-products. Describe equipment commonly used t o remove particulat es and harmful gases from combustion gases. Boiler Operation Describe the location and purpose of boiler vents. Describe the location and purpose of boiler drains. Explain what blowdown valves are. State the purpose of soot blowing. Describe the operation of a typical soot blower.
Subjects: Combustion Elements of Combustion Boiler Fuel Systems Fuel/Air Rat io Air and Gas Air and Gas Flow Path Pollution Cont rols Boiler Operation Vents, Drains, and Blowdown Valves Soot blowing Course 65 of 245
Process Operations
POWER PLANT BOILERS: Normal Operations (IHRDC_OM_AOBNO)
Overview: This is an interactive module designed to present an overview of the basic procedures for normal operations of a drum-type boiler. Trainees will learn what is meant by steady state conditions and efficiency, t he basic instrumentation used to monitor t he operation of a boiler, how steam temperature is controlled, and the basic procedures for ash handling. Duration: 2 hrs Objectives: Overview Explain what steady st at e conditions for a boiler are. Describe some of the syst ems and components that must be monitored during boiler operation under steady st at e conditions. Describe typical operator concerns associated with the energy losses that occur during normal operation of a boiler. Monitoring and Controlling Operations Describe basic operator responsibilit ies for monitoring a boiler's steam/water circuit . Describe typical control room instrumentation that is used to monitor a boiler's steam/water circuit. Describe basic operator responsibilit ies for monitoring combust ion and the air/gas circuit for a boiler. Describe typical control room instrumentation that is used to monitor combustion and the air/gas circuit for a boiler. Describe some of the basic systems and components checks that operators perform during normal boiler operation. Describe five methods that are used in power plants for controlling steam temperature. Ash Handling Describe the basic procedures for removing bottom ash. Describe the basic procedures for removing fly ash.
Subjects: Overview Steady State Conditions Energy Losses Monitoring and Controlling Operations The Steam/Water Circuit The Air/Gas Circuit Steam Temperature Ash Handling Bottom Ash Fly Ash Course 66 of 245
Process Operations
POWER PLANT BOILERS: Startup and Shutdown (IHRDC_OM_AOBSS)
Overview: This is an interactive training module designed to familiarize trainees wit h basic t echniques for start ing up and shutting down drum-type boilers. After completing this module, the t rainees should be able to describe basic procedures for performing a cold st artup of a drum-type boiler, light ing off the furnace, warming up the boiler and establishing the boiler flame. They should also be able to describe basic procedures for shut ting down a typical drum-type boiler. In addit ion, the trainees should be able to compare and contrast the startup and shut down of a drum-type boiler with the startup and shut down of a once-through boiler. Duration: 2 hrs Objectives: Basic Procedures Describe basic checks t hat boiler operat ors make during an initial pre-st artup walkthrough. Describe typical procedures for a cold startup of a controlled circulation, drumt ype boiler. Describe basic preparat ions for lighting off t he furnace, how light-off is initiated, and how a typical boiler is warmed up. Describe how pulverizers are start ed up and controlled. Describe how the main coal burners are ignited and controlled. Describe the basic procedures for shutting down a typical drum-t ype boiler. Once-Through Boilers Describe the basic differences and similarities bet ween the operation of a oncethrough boiler and a drum-type boiler. Describe how a steam/water separation system is used during the startup and the shutdown of a once-through boiler.
Subjects: Basic Procedures Cold Start up Light-off and Warmup Establishing a Boiler Flame Shutdown Once-Through Boilers Basic Operations Steam/Wat er Separation Course 67 of 245
Process Operations
POWER PLANT BOILERS: Water and Steam (IHRDC_OM_AOBWS)
Overview: This unit begins by explaining why wat er circulat es in a boiler, and describes the flow path of water through a typical drum-type boiler. Differences between natural circulation and controlled circulation are explained, and the components and functions of a typical boiler drum are examined. The unit goes on t o explain how the components found in a steam flow path affect the production and use of steam. The unit concludes with a look at what the critical point is, and why some boilers operate at or above critical conditions. Also covered is the operator's role in maintaining the correct st eam pressure in drum-type and once-through boilers. Duration: 2 hrs Objectives: Water State the purposes of water circulation in a boiler. Describe the water flow path through a typical drum-type boiler. Describe the basic principle of natural circulation and two fact ors that can affect it. Describe the differences between nat ural and controlled circulations. Describe the functions and components of a typical boiler drum. Steam Define: boiling, saturation, temperature, and superheat. Describe the st eam flow path from the boiler to the condenser in a typical generating unit. State the function of a superheater and describe how superheaters can be classified. State the function of a desuperheater. State the function of a reheater and describe how reheaters can be classified. Describe the basic operation of a condenser. Supercritical Boilers Define crit ical point . Explain why some boilers operate above the critical point. Describe the flow path of water in a once-through boiler. State the advantages and disadvantages of a once-through supercritical boiler. Explain how steam pressure is maintained in drum-type and once-through boilers.
Subjects: Water Water Flow Path Circulation Boiler Drum Steam Introduction Steam Flow Pat h Supercritical Boilers Critical Conditions Once-Through Boilers Boiler Operations Course 68 of 245
Process Operations
POWER PLANT OPERATION: Basic Principles (IHRDC_OM_AOOBP)
Overview: At t he complet ion of this inst ructional unit, trainees will be able to describe how plant systems respond to changes in load on a unit, and list operat or responsibilities during load changes. In addition, trainees will be able to describe the functions of bearings, operation of sliding surface bearings and rolling contact bearings, operator responsibilit ies associated with bearings, and how bearings are lubricated. Duration: 2 hrs Objectives: Load Changes Describe how a plant responds to changes in load on a unit. Describe the basic responsibilit ies of an operator during a load change. Bearings and Lubrication Describe two major types of bearings. Describe the basic functions of all bearings. Describe the operation of a typical sliding surface bearing. Describe the operation of rolling contact bearings. Describe some of the basic bearing checks operators perform. Describe how grease is used as a lubricant. Describe how oil is used as a lubricant .
Subjects: Load Changes Plant Responses Operator Responses Bearings and Lubrication Bearings Lubrication Course 69 of 245
Process Operations
POWER PLANT OPERATION: Safety and Pollution Control (IHRDC_OM_AOOSP)
Overview: Trainees are introduced to plant safety concepts t hrough a discussion of how a combination of plant procedures and common sense are used to protect operators on the job. They are also introduced to potential pollution problems in a power plant and t he equipment used to deal wit h these potential problems. Duration: 2 hrs Objectives: Plant Safety Describe some of the basic protect ive equipment that operators commonly use. Describe how a tagging system is used to provide protection t o personnel working on plant equipment. Pollution Control Ident ify a source of air pollution in a power plant. Describe some of the techniques used to control air pollut ion released by a plant. Ident ify a source of thermal pollution in a power plant. Describe operator responsibilities for monitoring thermal pollution leaving the plant. Ident ify a major source of water pollut ion in a power plant. Describe operator responsibilities for monitoring wastewater leaving t he plant . Describe some of the equipment that can be used to minimize the effects of noise pollution.
Subjects: Plant Safety Personal Protection Plant Safet y Pollution Control Air Pollut ion Thermal Pollution Water Pollution Noise Pollution Course 70 of 245
Process Operations
POWER PLANT TURBINES: Bearings and Operation (IHRDC_OM_AOTBO)
Overview: This interactive training unit is designed to familiarize trainees wit h basic principles associated with turbine shaft bearing lubrication, turbine speed control, and turbine operation. After completing this unit, trainees should be able to identify and describe the functions of the component s of a typical t urbine lube oil syst em. They should also be able to describe the basic components and operat ion of a typical turbine speed control system. In addition, they should be able to describe operator responsibilities associat ed with turbine startup, operation, and shut down. Duration: 2 hrs Objectives: Bearing Lubrication State the functions of the following basic components typically found in a turbine lube oil system: reservoir, main lube oil pump, boost er pump, and lube oil coolers. State the functions of the following addit ional components typically found in a turbine lube oil system: AC auxiliary pump, DC emergency pump, AC turning gear pump, and vapor extractor. Explain why it is important to make sure that t he controllers for t he standby oil pumps are in the standby or automatic positions. Describe a situation in which increase in bearing oil t emperature could indicate a problem. Describe a situation in which an increase in bearing oil temperature is considered normal. Turbine Control Ident ify two major systems commonly used to control t urbine speed. Describe the basic components of a turbine speed cont rol system. Describe how turbine speed is cont rolled by a mechanical-hydraulic cont rol system wit h a flyweight governor. Describe what happens when a turbine trip occurs. Turbine Operation Explain why the warmup period is important. Explain why it is important to prevent wat er buildup and describe how this is done. Describe the st eps involved in a typical shutdown procedure.
Subjects: Bearing Lubrication Basic Component s Additional Components Operator Responsibilities Turbine Control Basics Example Turbine Operation Startup Normal Operation and Shutdown Course 71 of 245
Process Operations
POWER PLANT TURBINES: Boiler and Turbine Protection (IHRDC_OM_AOPPB)
Overview: This unit describes the basic operat ion and startup requirements of a balanced-draft, controlled circulation, drum-type boiler. It also identifies common problems that affect the combustion side of a boiler and the water and steam side of a boiler, and it describes automatic controls and operat or actions that address those problems. The unit goes on to describe common t urbine problems, including temperature- and pressure-related problems, overspeed, vibration and eccentricity. Automat ic protective devices and operator actions t hat address those problems are also described. Duration: 2 hrs Objectives: Boilers Describe the basic operation of a balanced-draft, controlled circulation, drumtype boiler. Ident ify and describe the basic requirements for starting up a boiler. Ident ify common boiler combustion problems. Describe automatic controls that regulate the combustion process. Describe actions t hat operators can take to address combustion problems. Ident ify aut omatic protect ive devices associated wit h the combust ion process. Ident ify common problems that occur on t he water and steam side of a boiler. Describe actions t hat operators can take to address water and steam problems. Ident ify aut omatic protect ive devices associated wit h the boiler steam/water cycle. Turbines Ident ify common temperature-related and pressure-related turbine problems. Describe actions t hat operators can take to address turbine problems related t o temperat ure and pressure. Ident ify aut omatic protect ive devices associated wit h temperat ure and pressure problems. Describe turbine problems associated wit h overspeed, vibration and eccentricit y. Describe actions t hat operators can take to address overspeed, vibration and eccentricity problems. Ident ify aut omatic protect ive devices associated wit h overspeed, vibration and eccentricit y problems.
Subjects: Boilers Basic Operation and Startup Combustion Problems Water and St eam Problems Turbines Temperature and Pressure Problems Overspeed, Vibration and Eccentricity Course 72 of 245
Process Operations
POWER PLANT TURBINES: Condensate and Feedwater Systems (IHRDC_OM_AOCFS)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic layout of a typical condensate and feedwater system and the basic operation of the system's individual components. After completing this unit, t rainees should be able to identify the components in a condensate and feedwater system and describe the basic operation of each component . They should also be able to explain how the system normally operat es, describe operator responsibilities associat ed with normal operation, and identify some common operat ing problems. Duration: 2 hrs Objectives: System Overview Describe the basic layout of a t ypical condensate and feedwater system. Describe the basic function and operation of the individual components in a typical condensat e and feedwater system. System Operation Describe the normal operation of a typical condensate and feedwat er system and identify typical operator responsibilities that are associated with normal operation. Ident ify and describe some common operating problems that may occur in a condensate and feedwater system and describe basic steps for dealing with these problems.
Subjects: System Overview System Layout System Components System Operation Normal Operation Operating Problems Course 73 of 245
Process Operations
POWER PLANT TURBINES: Condenser and Circulating Water (IHRDC_OM_AOPPC)
Overview: This training unit provides basic information about t he design and function of power plant condensers and circulating water systems. It describes the operation of a single-pass condenser and a two-pass condenser, as well as various air removal system components. The unit also covers the basic operation of a once-t hrough circulating water system, and it describes how mechanical draft cooling towers and natural draft cooling towers work. Duration: 2 hrs Objectives: Condensers Describe the basic function of a condenser. Describe the operation of a single-pass condenser and a two-pass condenser. Describe the basic function of an air removal system. Describe the operation of a reciprocating vacuum pump, a rotary vacuum pump and an air ejector. Ident ify and describe routine checks that operat ors should perform on a condenser. Circulating Water Systems Describe the basic operation of a once-through circulat ing wat er system. Describe how mechanical draft cooling towers and natural draft cooling towers function.
Subjects: Condensers Function and Design Air Removal Syst ems Condenser Operation Circulating Water Systems Once-Through Systems Cooling Towers Course 74 of 245
Process Operations
POWER PLANT TURBINES: Fundamentals (IHRDC_OM_AOPPF)
Overview: This interactive training unit is designed to familiarize trainees wit h various types of hazards t hat may exist in a power plant. Aft er completing t his unit, the trainees should be able to identify common types of mechanical and electrical hazards, t emperature and pressure hazards, and fire and chemical hazards. They should also be able to describe devices and t echniques that can be used to prevent or minimize t hese hazards. Duration: 2 hrs Objectives: Mechanical & Electrical Describe conditions that commonly lead t o material and equipment failure. Ident ify ways to detect equipment failure. Describe common electrical hazards in a power plant. Ident ify devices used t o prevent or minimize elect rical hazards. Temperature & Pressure Ident ify devices used t o prevent abnormal t emperature conditions. Ident ify devices used t o prevent abnormal pressure conditions. Chemical & Fire Ident ify common chemical hazards in a power plant Ident ify ways to prevent chemical hazards. Describe fire protection systems commonly found in power plants.
Subjects: Mechanical & Electrical Equipment Failure Electrical Hazards Temperature & Pressure Abnormal Temperature Abnormal Pressure Chemical & Fire Chemical Hazards Fire Prot ection Course 75 of 245
Process Operations
POWER PLANT TURBINES: Integrated Systems (IHRDC_OM_AOPPI)
Overview: In this unit , trainees will learn what logic diagrams are and how they are used to represent the functions carried out by plant protection equipment. Common types of logic gates are identified and described, and interlock logic is examined. The unit also describes how logic diagrams can be used to represent conditions t hat cause boiler trips, turbine trips and generator trips, and it explains how the protection systems for boilers, t urbines and generators are int errelated. Duration: 2 hrs Objectives: Logic Diagrams Describe what logic diagrams are and how they can be used to represent functions carried out by plant protection equipment. Describe the functions of AND gates, OR gates, NOT gates and time delay (TD) gates in logic circuits. Describe what interlocks are and how the actions of interlocks associated with boiler operations are represented in logic diagrams. Trip Logic Describe how logic diagrams can be used to represent conditions that cause equipment trips. Ident ify conditions that can cause a boiler trip and describe how a logic diagram can be used to illustrat e t hose conditions. Ident ify conditions that can cause a turbine trip and describe how a logic diagram can be used to illustrate t hose conditions. Ident ify conditions that can cause a generator trip and describe how a logic diagram can be used to illustrate t hose conditions. Describe how the protection systems for boilers, turbines and generat ors are interrelat ed.
Subjects: Logic Diagrams Overview Logic Gates Interlock Logic Trip Logic Boiler Trips Turbine Trips Generat or Trips Integrated Protection Course 76 of 245
Process Operations
POWER PLANT TURBINES: Power and Energy (IHRDC_OM_AOPPE)
Overview: This unit will introduce trainees to basic component s of a power system and describe how these component s are arranged to deliver power to customers. It will also examine t he energy conversions that are necessary to produce power in a power plant and discuss basic principles of how an operat or responds to emergency conditions. Duration: 2 hrs Objectives: The Power System State the function of a generator. Define t he following terms: unit, watt, and megawat t. Describe how power is typically dist ribut ed to customers. Define t he following terms: switchyard, substations, and power system. Define demand. Describe the function of the load dispatcher. Explain why there are variations in demand. Explain why supply must always equal demand. Energy Conversion Explain how energy is converted to produce electricit y in fossil fuel plants. State some of the advantages and disadvantages of fossil fuel plants. Explain how energy is converted to produce electricit y in gas turbine plants. State some of the advantages and disadvantages of gas turbine plants. Explain how energy is converted to produce electricit y in nuclear plants. State some of the advantages and disadvantages of nuclear plants.
Subjects: The Power System Generat ing Power Distributing Power Demand Energy Conversion Fossil Fuel Plant s Gas Turbine Plants Hydroelect ric Plants Nuclear Power Plant s Course 77 of 245
Process Operations
POWER PLANT TURBINES: Power Generation (IHRDC_OM_AOPGE)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion of an AC generator and auxiliary systems and components associated with it. After completing this unit, trainees should be able to explain how volt age is induced in an AC generator, how an AC generator produces current , and how an AC generator can be cooled. Duration: 2 hrs Objectives: Generating Electricity Name the basic parts of a generator and describe the function of each in inducing voltage. Describe the primary difference between a single-phase generator and a threephase generator. Name two factors that determine the frequency of t he current produced by a generator. Explain why the frequency of a generat or's output must be controlled. Explain the function of the excit er in a generator. Name the parts of a DC exciter and the parts of a brushless exciter and describe their functions. Generator Cooling Explain why a large generator is typically cooled with hydrogen instead of air. Explain the function of an oil seal in a hydrogen-cooled generator. Describe how hydrogen is supplied t o a generator cooling system. Explain the purpose of each of t he following components in a hydrogen generator cooling system: purity analyzer, core monit or, hydrogen dryer, liquid det ector. Explain how carbon dioxide and air are used t o purge a generat or cooling system. Describe the flow of water in a t ypical stator cooling system. Describe the function of each of the following component s in a typical stator cooling system: temperature cont rol valve, pressure control valve, demineralizer.
Subjects: Generating Electricity Principles of Induction Out put Frequency Generat or Excitation Generator Cooling Hydrogen Cooling Cooling Auxiliary Systems Gas Purging Stator Cooling Syst em Course 78 of 245
Process Operations
POWER PLANT TURBINES: Steam Cycle (IHRDC_OM_AOPSC)
Overview: In this unit , main component s of t he steam cycle in a fossil fuel fired power plant will be identified. The unit will also trace the order in which steam and water flow through these components in order to show how the components are arranged. Duration: 2 hrs Objectives: Components Describe how a boiler works. Describe how fuel and air are supplied to a boiler. Describe how a turbine works. Describe how a condenser works. Describe the function of the condensate-feedwater system. Describe the function of the circulating water system. Describe the function of the makeup water system. Flow Describe how steam and water move through the st eam cycle. Describe how the flow of steam and the flow of water are controlled. Describe how the flow of fuel to the boiler can be controlled. Describe three general actions that must be t aken during any emergency. Describe the emergency act ions that must be taken if there is a loss of flame in the boiler.
Subjects: Components Boilers Turbines Condensers Flow Movement of Steam and Water Steam and Water Flow Control Fuel Flow Control Emergencies Course 79 of 245
Process Operations
POWER PLANT TURBINES: Steam Flow (IHRDC_OM_AOTSF)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic principles associated with t he construction and operation of steam turbines. After completing this unit , trainees should be able to state the functions of t he main parts of a t ypical turbine and describe how steam causes impulse blades and reaction blades to t urn a turbine's wheels. They should also be able to describe the purpose and operat ion of a gland steam seal system, a gland st eam seal exhaust system, a carbon seal, and a wat er seal. Duration: 2 hrs Objectives: Construction and Rotation State the functions of the following t urbine parts: wheels, blades, diaphragms, steam chest , nozzle block, and rotor. State the functions of stop valves and cont rol valves. Describe how steam causes impulse blades to turn a turbine's wheels. Describe how steam causes reaction blades to t urn a turbine's wheels. State the functions of reheat stop valves and intercept valves. Define a turbine trip and describe how it protects a t urbine. Sealing Systems Describe the purpose for and operat ion of a gland steam seal system. Describe the purpose for and operat ion of a gland steam seal exhaust system. Describe the operation of a carbon seal. Describe the operation of a water seal.
Subjects: Construction and Rotation Construction Rotation Sealing Systems Steam Seals Carbon and Wat er Seals Course 80 of 245
Process Operations
POWER PLANT TURBINES: Steam Systems (IHRDC_OM_AOPPS)
Overview: This is an interactive training module designed to present basic information on the steam/wat er cycle in a power plant . Specific att ention is directed to the main st eam system, the reheat steam system, the extract ion steam system and the auxiliary st eam system. Basic procedures for a plant startup and several operator checks on steam systems and component s are also included. Duration: 2 hrs Objectives: Systems and Components Describe how steam flows t hrough the various steam systems that make up a typical power plant's st eam/water cycle. Ident ify the component s of a main steam system and describe their functions. Ident ify the component s of a reheat st eam system and describe their functions. Explain why steam piping contains expansion loops and bends. Ident ify the component s of an extraction steam system and describe their functions. Explain how an extraction steam system improves plant efficiency. Describe typical uses of auxiliary steam in a power plant. Ident ify some t ypical components of an auxiliary st eam system and describe their functions. Describe how the components that cont rol the pressure and temperature of auxiliary steam operate. Systems Operations Describe some basic procedures for removing accumulated condensate and gradually warming up steam systems components during a plant startup. Describe some basic checks that operators should make to ensure that steam systems and their components are operating properly.
Subjects: Systems and Components Steam/Wat er Cycle Main Steam Syst em Reheat Steam System Extraction Steam System Auxiliary Steam System Systems Operations Plant Startup Systems Inspections Course 81 of 245
Process Operations
PROCESS SAMPLING: Obtaining Samples (IHRDC_OM_AOPOS)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic concepts associated with obtaining samples of process materials. After completing this unit, trainees should be able to describe hazards associat ed with sampling and t he precautions that may be required. They should also be able to take contaminant-free representative samples of process liquids, solids, and gases. Duration: 2 hrs Objectives: Introduction Explain why samples are taken in process systems. Describe some hazards associated with sampling mat erials. Describe protective clothing that should be worn when taking samples of hazardous and non-hazardous materials. Describe two types of respirat ors worn when sampling involves materials that produce harmful dust part icles or t oxic fumes. Liquids Describe how to keep liquid samples from being cont aminated when they are taken. Explain how to make sure that a representative sample of a liquid is obtained. Describe information typically included on a sample label. Solids and Gases Describe how to obtain cont aminant-free represent at ive samples of process solids. Describe how to obtain cont aminant-free represent at ive samples of process gases.
Subjects: Introduction Basic Principles Prot ective Clothing Respirators Liquids Preparing to Sample Obtaining a Sample Labeling a Sample Solids and Gases Sampling Solids Sampling Gases Course 82 of 245
Process Operations
PROCESS SAMPLING: Testing Samples (IHRDC_OM_AOPTS)
Overview: This interactive training unit is designed to familiarize trainees wit h basic procedures for performing test s on samples of process materials and product s. After completing this unit, trainees should be able to describe how t o perform a pH test , a percent solids test , a specific gravit y test , and a t itration. They should also be able to describe t he operat ion of a gas chromatograph and how it is used to perform t ests on complex gas mixtures or solutions. Duration: 2 hrs Objectives: pH and Percent Solids Describe how a pH t est is performed. Describe how a percent solids t est is performed. Specific Gravities and Titrations Describe how a specific gravity test is performed. Describe how a titration is performed. Gas Chromatographs Describe how a gas chromatograph operates. Describe how to perform a gas chromatograph t est.
Subjects: pH and Percent Solids pH Tests Percent Solids Tests Specific Gravities and Titrations Specific Gravity Test s Titrations Gas Chromatographs Operation Performing a Test Course 83 of 245
Process Operations
PUMPS: Basic Types and Operation (IHRDC_OM_AOPBT)
Overview: This interactive training unit is designed to int roduce trainees to the basic components and operation of positive displacement pumps and centrifugal pumps. After completing this unit, trainees should be able to explain how pumps can be identified, identify the basic components of a pump, and describe the functions of various types of pump auxiliary equipment and systems. They should also be able t o describe the general operation of reciprocating and rotary positive displacement pumps, and single-st age and multistage centrifugal pumps. Duration: 2 hrs Objectives: Pump Fundamentals Given a simple syst em diagram, locate each pump, tell what it does, and ident ify it by one or more names. Ident ify the casing, the inlet , and the out let on a pump. Name two general categories of pumps. Explain the functions of the following t ypes of pump auxiliary equipment and systems drivers, couplings, strainers, lubricating syst ems, packing, and mechanical seals. Positive Displacement Pumps Describe the general operation of a reciprocating positive displacement pump. Describe the general operation of a rotary positive displacement pump. Centrifugal Pumps Describe the general operation of a single-stage cent rifugal pump. Describe the general operation of a multistage centrifugal pump.
Subjects: Pump Fundamentals Pump Identification Pump Component s Auxiliary Equipment Positive Displacement Pumps Reciprocating Pumps Rotary Pumps Centrifugal Pumps Single-Stage Pumps Multistage Pumps Course 84 of 245
Process Operations
PUMPS: Fundamentals of Centrifugal Types (IHRDC_OM_AOPFC)
Overview: This interactive training unit is designed to int roduce trainees to the fundamental operating principles of single-stage and multistage centrifugal pumps. After completing this unit, trainees should be able to describe the general operating principles of a centrifugal pump. Specifically, t hey should be able to describe the differences between radial, axial, and mixed flow pumps, and describe the basic operation of a vertically-mounted and multistage pump. Trainees should also be able t o describe the purpose and the basic operation of a mechanical seal flush system. Duration: 2 hrs Objectives: Centrifugal Pump Operation Describe general operating principles of a centrifugal pump. Explain differences between radial flow, axial flow, and mixed flow pumps. Explain the principles of operation of a vertically mounted centrifugal pump. Describe the basic operation of a typical multistage centrifugal pump. Describe two ways that mult istage centrifugal pumps can minimize axial thrust. Centrifugal Pump Components Explain the differences between an open impeller, a closed impeller, and a semi-open impeller. Compare and contrast a single-suction impeller and a double-suction impeller. Describe the general design and function of a diffuser. Describe the purpose and basic operation of a mechanical seal flush system.
Subjects: Centrifugal Pump Operation Principles of Operat ion Vertical Pumps Multistage Pumps Centrifugal Pump Components Impellers and Diffusers Mechanical Seal Systems Course 85 of 245
Process Operations
PUMPS: Operation of Centrifugal Types (IHRDC_OM_AOPOC)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion of centrifugal pumps. After complet ing t his unit, trainees should be able t o describe techniques for priming a centrifugal pump and explain general procedures for st arting and shut ting down a pump. Trainees should also be able to describe some general checks that may be made on an operating pump and describe operator concerns related to air and vapor binding in a centrifugal pump. Duration: 2 hrs Objectives: Startup and Shutdown Describe techniques used to prime a centrifugal pump. Describe a procedure for starting up a cent rifugal pump. Describe a procedure for shut ting down a centrifugal pump. Pump Operation Describe checks that should be made on an operating centrifugal pump and its auxiliary equipment. Describe indications of air binding and vapor binding in a pump and some of the possible sources of in-leakage t o a pump.
Subjects: Startup and Shutdown Priming Pump Startup and Shutdown Pump Operation Operator Checks Air Binding and Vapor Binding Course 86 of 245
Process Operations
PUMPS: Performance and Inspection (IHRDC_OM_AOPER)
Overview: This interactive training unit is designed to int roduce trainees to fact ors that affect the performance of pumps and some of the symptoms of improper pump operation. After complet ing this unit, trainees should be able to ident ify and explain the relationship bet ween various factors that affect pump performance, and to explain how pump performance can be evaluated. They should also be able to identify symptoms of some common pump problems and explain how to check a pump for signs of problems such as leaks and cavitation. Duration: 2 hrs Objectives: Pump Performance Define and explain t he relat ionship between the following: static head, dynamic head, suction head, discharge head, and total head. Describe some basic ways pump performance can be determined. Explain the relationship bet ween minimum net positive suction head and cavitation. Pump Inspection Ident ify symptoms that may indicat e abnormal pump operation. Ident ify pump components that should be checked for leaks. Describe common symptoms of cavitation. List some ways to stop or minimize cavitation.
Subjects: Pump Performance Head Suction Head and Cavitation Pump Inspection Sympt oms of Pump Problems Checking for Leaks Checking for Cavitation Course 87 of 245
Process Operations
PUMPS: Reciprocating Positive Displacement Types (IHRDC_OM_AOPRE)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic parts and operation of several t ypes of reciprocating positive displacement pumps. After completing this unit, t rainees should be able to describe the general operation of the following t ypes of pumps: single-acting piston pumps, single-acting plunger pumps, double-acting piston pumps, duplex pist on pumps, motor-driven diaphragm pumps, and air-operated diaphragm pumps. Trainees should also be able to describe a general procedure for start ing up and shutting down a t ypical reciprocat ing pump, and t o explain the function and operation of a relief valve. Duration: 2 hrs Objectives: Piston and Plunger Pumps Describe the general operation of a single-acting piston pump. Describe the general operation of a plunger pump. Describe the general operation of a double-acting piston pump. Describe the general operation and an advantage of a duplex piston pump. Diaphragm Pumps Describe the general operation of a mot or-driven diaphragm pump. Describe the general operation of an air-operated diaphragm pump. Pump Operation Describe a general procedure for starting up a reciprocating pump. Describe a general procedure for shutting down a reciprocating pump. Explain the purpose of a relief valve.
Subjects: Piston and Plunger Pumps Single-Acting Pumps Double-Act ing Pumps Duplex Pumps Diaphragm Pumps Motor-Driven Diaphragm Pumps Air-Operated Diaphragm Pumps Pump Operation Pump Startup and Shutdown Relief Valves Course 88 of 245
Process Operations
PUMPS: Rotary Positive Displacement Types (IHRDC_OM_AOPRP)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic parts and operation of several t ypes of rotary posit ive displacement pumps. After completing this unit, trainees should be able to describe the general operation of t he following types of pumps: screw pumps, gear pumps, lobe pumps, vane pumps, and tubing pumps. They should also be able to describe a general procedure for start ing up and shutting down a t ypical rot ary pump, and t o explain the function and operation of a relief valve. Duration: 2 hrs Objectives: Types of Rotary Pumps Describe the general operation of a progressive cavity pump. Describe the general operation of a two-screw pump. Describe the general operation of an external gear pump and an internal gear pump. Describe the general operation of a lobe pump. Describe the general operation of a sliding vane pump and a flexible vane pump. Describe the general operation of a tubing pump. Operating Procedures Describe procedures involved in starting up a rotary positive displacement pump. Describe procedures involved in shutting down a rotary positive displacement pump. Explain the purpose of a relief valve.
Subjects: Types of Rotary Pumps Screw Pumps Gear and Lobe Pumps Vane Pumps Tubing Pumps Operating Procedures Rotary Pump Startup and Shutdown Relief Valves Course 89 of 245
Process Operations
REFRIGERATION SYSTEM: Basic Concepts (IHRDC_OM_AORBC)
Overview: This interactive training unit is designed to int roduce trainees to some of the basic principles of refrigeration system operation. Aft er completing t his unit, trainees should be able t o explain what refrigerat ion is and how heat transfer occurs in a refrigeration system. They should also be able to describe the basic parts, or steps, of a refrigerat ion cycle and explain how t hese steps can be carried out by specific refrigeration system components. Duration: 2 hrs Objectives: Fundamentals Define refrigeration. Explain what a refrigerant is. Explain the basic difference between sensible heat transfer and latent heat transfer. Describe how pressure and temperature can affect heat transfer. Define heat source and heat sink. Refrigeration Systems Describe the processes involved in a typical refrigeration cycle. Describe the devices that accomplish the basic functions of a typical refrigeration cycle. Explain how a refrigeration system can be used with a secondary cooling system.
Subjects: Fundamentals Introduction t o Refrigeration Heat Transfer Refrigeration Systems Basic Refrigeration Cycle Refrigeration Components Secondary Cooling Systems Course 90 of 245
Process Operations
REFRIGERATION SYSTEM: Operation (IHRDC_OM_AOROP)
Overview: This interactive training unit is designed to familiarize trainees wit h the operation of vapor compression refrigeration systems and absorpt ion refrigeration systems. After completing this unit , trainees should be able to describe the components and operations of a vapor compression system and an absorption system. They should also be able to describe control devices, indicat ing inst ruments, and operator checks associated with t hese systems, and identify some operating problems that may occur. Duration: 2 hrs Objectives: Types of Systems Ident ify the component s of a typical vapor compression refrigerat ion syst em. Describe the operation of a vapor compression refrigeration system. Describe the operation of one type of absorption refrigeration system. System Operation Describe some control devices commonly used with refrigerat ion syst ems. Describe some monitoring and indicat ing inst ruments commonly used with refrigeration systems. Describe some operator checks commonly performed on a refrigerat ion syst em. Ident ify some operating problems that may occur in a typical refrigeration system.
Subjects: Types of Systems Vapor Compression System Absorption System System Operation Controls Indicators and Checks Operating Problems Course 91 of 245
Process Operations
STATISTICAL PROCESS CONTROL: Basic Control Charts (IHRDC_OM_AOSBC)
Overview: This interactive training unit is designed to familiarize trainees wit h some of the basic control charts used in Statistical Process Control (SPC). After completing this unit, t rainees should be able to describe the characteristics of X+ charts, R charts, moving X+ charts, moving R chart s, and individual X charts. They should also be able to explain what each chart represent s and how to plot values on each chart. Duration: 2 hrs Objectives: Control Charts - 1 Describe how SPC is helpful in responding to an out-of-control process. Explain what X+ charts represent. Describe how to plot values on an X+ chart. Explain what R charts represent. Describe how to plot values on an R chart . Explain why an X+ and an R chart are commonly used t ogether. Describe how to recognize abnormal variat ions on X+ charts and R charts. Control Charts - 2 Describe the characteristics of moving X+ chart s. Describe how to plot values on a moving X+ chart. Describe the characteristics of moving R charts. Describe how to plot values on a moving R chart. Describe the characteristics of individual X charts. Describe how to plot values on an individual X chart .
Subjects: Control Charts - 1 SPC and Control Charts X+ Charts R Charts Examples Control Charts - 2 Moving X+ Charts Moving R Charts Individual X Charts Course 92 of 245
Process Operations
STATISTICAL PROCESS CONTROL: Introduction (IHRDC_OM_AOSIN)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic principles of Statist ical Process Control (SPC). Aft er completing this unit, t rainees should be able to explain what SPC is and how it can be applied t o a process. They should also be able to describe the basic element s of an SPC control chart and relate an SPC control chart to an X-Y graph and to a normal distribution curve. Duration: 2 hrs Objectives: What is SPC? Define quality in terms of the process industry. Explain what Statistical Process Control (SPC) is. Describe the benefits of SPC. Describe how SPC was developed. Applying SPC Describe what a process is. Ident ify factors that affect a process. Describe the t wo basic types of variation in a process. Ident ify factors that affect how SPC is applied to a process. Charts Describe how to plot values on a basic X-Y graph. Explain what a histogram is and how it relates to SPC cont rol charts. Explain what a st andard deviation is. Ident ify the basic elements of a typical Shewhart cont rol chart. Relate a Shewhart control chart to a normal distribution curve.
Subjects: What is SPC? SPC and Product Quality Origin of SPC Applying SPC Factors Affecting a Process Application t o a Process Charts X-Y Graph Histogram Shewhart Control Chart Course 93 of 245
Process Operations
STATISTICAL PROCESS CONTROL: Process Variations (IHRDC_OM_AOSPV)
Overview: This interactive training unit is designed to familiarize trainees wit h some basic techniques for using Statist ical Process Control (SPC) to recognize and respond to variations in plant processes. After completing this unit, t rainees should be able to describe how plotted values on control charts can be interpreted, describe how an operator can use SPC to recognize and respond to out-of-control conditions and process inst ability, describe basic considerat ions for using SPC with a computer, and explain how t o use various types of at tribute charts. Duration: 2 hrs Objectives: Control Charts Describe how plotted values on control charts can be interpreted. Describe common patt erns of instability and identify conditions t hat can cause these patterns to occur. Operating with SPC Describe how an operator can use SPC t o recognize and respond t o problems in a process. Define CUSUM and explain how it can be used. Describe how using CUSUM compares to using control charts. Describe two common causes of an off-aim condition. Describe how to reset CUSUM and how to set a new aim. Attribute Charts Define t he terms defect and defective product. Describe how to use C charts, U Chart s, NP charts, and P charts.
Subjects: Control Charts Interpreting Charts Recognizing Patt erns Operating With SPC Using SPC CUSUM Attribute Charts Types of Charts Course 94 of 245
Process Operations
TROUBLESHOOTING: Basic Concepts (IHRDC_OM_AOPOB)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with troubleshooting a problem in a process system. After complet ing this unit, trainees should be able to explain what t roubleshooting is, and how it can be carried out as a systematic, logical procedure. They should also be able to explain how to apply the major steps of a basic t roubleshooting procedure to a problem in a process. Duration: 2 hrs Objectives: Introduction Define t roubleshooting. Ident ify and describe the main steps involved in troubleshooting. Ident ify various sources of information that can be used for troubleshooting. Explain how the following process of elimination met hods are applied in troubleshooting: input /output test ing, bracketing, the serial met hod, and the half-splitting method. Troubleshooting Describe a basic wast ewat er treatment process. Describe how to troubleshoot a problem in a wastewater treatment process.
Subjects: Introduction What is Troubleshooting? Process of Elimination Troubleshooting Process Problem Course 95 of 245
Process Operations
TROUBLESHOOTING: Process Examples (IHRDC_OM_AOPOP)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with troubleshooting problems in process systems. After completing this unit, trainees should be able to follow a logical, systematic troubleshooting procedure to identify and correct process problems. Duration: 2 hrs Objectives: Exercise 1 - Tank Level Describe how troubleshooting techniques can be used to find and correct a problem in a process system. The system in this example transfers liquid from a storage tank to a process feed tank. Exercise 2 - Fluid Transfer Describe how troubleshooting techniques can be used to find and correct a problem in a process system. The system used in t his example t ransfers feed material to a dist illation process. Exercise 3 - Process Column Describe how troubleshooting techniques can be used to find and correct a problem in a process system. The system used in t his example is a dist illation process.
Subjects: Exercise 1 - Tank Level Exercise 2 - Fluid Transfer Exercise 3 - Process Column Course 96 of 245
Process Operations
VALVES: Basic Types and Operation 1 (IHRDC_OM_AOVB1)
Overview: This interactive training unit is designed to int roduce trainees to the basic parts and operation of valves commonly used in process systems. After completing this unit, trainees should be able to describe the purpose and uses of valves in process systems, identify the main part s of a typical valve, and describe the function of each part. They should also be able to describe t he specific uses, parts, and operat ion of gate valves, globe valves, plug valves, ball valves, and butterfly valves. Duration: 2 hrs Objectives: Introduction to Valves Describe purposes and uses of valves in process systems. Describe how valves are lined up. Ident ify main parts of a typical valve and their functions. Describe flanged, threaded, and welded methods of att aching valves t o piping systems. Describe the locations of typical valve leaks and how to stop a packing leak. Describe one method of lubricating a t ypical valve. Valve Types Describe the function and operation of gate valves. Describe typical applications of gate valves. Describe the functions and operation of globe and needle valves and t heir typical applicat ions. Ident ify a plug valve and describe its function and operation. Ident ify a t hree-way and a four-way valve and describe their function and operat ion. Describe typical applications of plug valves. Ident ify a ball valve and describe its function and operation. Describe typical applications of ball valves. Ident ify a butterfly valve and describe its function and operat ion. Describe typical applications of butterfly valves.
Subjects: Introduction to Valves Valves and the Process Syst em Valve Parts Valve Problems and Maintenance Valve Types Gate Valves Glove Valves Plug Valves Ball Valves Butterfly Valves Course 97 of 245
Process Operations
VALVES: Basic Types and Operation 2 (IHRDC_OM_AOVB2)
Overview: This interactive training unit is designed to int roduce trainees to some valves that are commonly used to isolate components, t o thrott le flow, to prevent reverse flow through a process system, and to protect systems from overpressure conditions. Aft er completing this unit, t rainees should be able to identify and describe t he basic functions and operat ion of diaphragm valves, pinch valves, and check valves. They should also be able t o explain how relief valves and safety valves protect syst em equipment and piping from excessive pressure. Duration: 2 hrs Objectives: Valve Types Ident ify a diaphragm valve and describe its functions and operation. Ident ify a pinch valve and describe its functions and operation. Ident ify swing check valves, lift check valves, and ball check valves, and describe their functions and operation. Relief and Safety Valves Describe the function and operation of relief valves. Describe typical uses of relief valves. Describe the function and operation of safety valves. Describe typical uses of safety valves.
Subjects: Valve Types Diaphragm Valves Pinch Valves Check Valves Relief and Safety Valves Relief Valves Safety Valves Course 98 of 245
Process Operations
VALVES: Electric and Hydraulic Actuators (IHRDC_OM_AOVEH)
Overview: This interactive training unit is designed to int roduce trainees to various types of electric and hydraulic actuators that are used t o control valves in process systems. After completing this unit, trainees should be able to describe the basic operation of solenoid actuators, motor-operated actuators, and various types of hydraulic act uators. They should also be able to explain t he funct ion of a pilot valve and describe problems associated with hydraulic act uators. Duration: 2 hrs Objectives: Electric Actuators Describe the basic operation of a solenoid actuat or. Describe the basic operation of a motor-operated act uator. Describe the function of torque swit ches. Describe the function of limit switches. Hydraulic Actuators Describe the operation of a single-acting, spring-return hydraulic actuator. Describe the basic operation of a double-acting hydraulic act uator. Describe the function of a pilot valve. Describe some ways to identify actuator problems.
Subjects: Electric Actuators Solenoid Actuat ors Motor-Operated Actuat ors Hydraulic Actuators Single-Acting Hydraulic Actuators Double-Act ing Hydraulic Actuat ors Pilot Valves Hydraulic Actuator Problems Course 99 of 245
Process Operations
VALVES: Introduction of Actuators (IHRDC_OM_AOVIA)
Overview: This interactive training unit is designed to int roduce trainees to actuators in general, and pneumatic act uators, in part icular. Aft er completing t his unit, trainees should be able t o identify and describe three basic types of actuators and explain how actuators position control valves. They should also be able to describe the basic design and operation of single- and doubleacting diaphragm actuators, single- and double-act ing piston actuators, van actuators, and positioners. Finally, trainees should be able to describe some common actuator problems. Duration: 2 hrs Objectives: Actuators and Control Valves Define actuator and describe three basic types of actuators. Describe the function of an actuat or. Describe the function of a controller. Describe the function of a control valve. Pneumatic Actuators Describe the basic design and operation of single-acting diaphragm and double-acting actuators. Describe the basic operation of single-acting and double-act ing piston actuators. Describe the basic operation of a vane actuator. Describe the function and basic operation of a positioner. Describe some ways to identify actuator problems. Describe some ways that an operat or can identify actuator problems. Describe a general procedure for handling a cont rol valve failure.
Subjects: Actuators and Control Valves Types of Actuators Control Valves Pneumatic Actuators Single-Acting Diaphragm Actuat ors Double-Act ing Diaphragm Actuators Single- and Double-Act ing Piston Actuators Van Actuators Positioners Actuator Problems Course 100 of 245
MAINTENANCE CURRICULUM
Operations & Maintenance e-Learning
Maintenance
BEARINGS: Fundamentals (IHRDC_OM_AMBIN)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion and maintenance of bearings. After completing this unit, t rainees should be able to describe the basic functions of bearings, the various types of sliding surface and rolling contact bearings, and the procedures for removing a rolling contact bearing from a shaft . They should also know how to install a rolling contact bearing on a shaft. Duration: 2 hrs Objectives: Bearing Basics State three basic functions of bearings. Describe two basic categories of bearings. Describe journal bearings and how they are constructed. Describe thrust bearings and how they are construct ed. Describe basic methods of lubricating sliding surface bearings. Describe common types of sliding surface bearing failures. Describe the basic construction of a typical rolling contact bearing. Describe each of the following rolling cont act type bearings: shallow groove ball bearings, deep groove ball bearings, spherical race ball bearings, cylindrical roller bearings, t apered roller bearings, barrel roller bearings, needle roller bearings, rolling cont act t hrust bearings, and angular cont act bearings. Explain how rolling contact bearings can be lubricated. Describe common types of rolling contact bearing failures. Bearing Maintenance Describe a procedure for removing a rolling contact bearing from a shaft . Describe a procedure for cleaning and inspect ing a rolling contact bearing. Describe a procedure for installing a new rolling contact bearing on a shaft.
Subjects: Bearing Basics Operation Sliding Surface Bearings Rolling Contact Bearings Bearing Maintenance Bearing Removal Bearing Inst allation Course 101 of 245
Maintenance
BEARINGS: Rolling Contact (IHRDC_OM_AMBRB)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion and maintenance of rolling contact bearings. After completing this unit, trainees should be able to describe common t ypes of rolling cont act bearings, and explain how they can be mounted and lubricated. Trainees should also be able t o explain how to remove a failed rolling contact bearing and how to install a new one. Duration: 2 hrs Objectives: Basic Concepts Describe the basic functions of a bearing. Ident ify the basic parts of a typical rolling contact bearing. Describe common types of ball bearings. Describe common types of roller bearings. Explain the difference between a press fit and a push fit. Describe common methods of mount ing rolling cont act bearings. Describe types of bearing housings. Describe a common oil lubrication system for rolling cont act bearings. Describe a common method of greasing a bearing. Bearing Failure and Removal Describe symptoms and causes of common types of rolling contact bearing failures. Describe a procedure for removing a rolling contact bearing from a shaft . Installation Describe preparations for installing a new rolling cont act bearing. Describe a procedure for installing a rolling contact bearing.
Subjects: Basic Concepts Functions and Features Types of Bearings Mountings and Housings Lubrication Bearing Failure and Removal Types of Failures Removal Technique Installation Preparing for Installation Installation Course 102 of 245
Maintenance
BEARINGS: Sliding Surface (IHRDC_OM_AMBSB)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion and maintenance of sliding surface bearings. After completing this unit, trainees should be able to describe common t ypes of journal bearings and t hrust bearings, and explain how sliding surface bearings can be lubricated. They should also be able to describe common indications of bearing performance and common types of sliding surface bearing failures. Additionally, they should be able to describe procedures for disassembling, inspecting, and reassembling journal bearings and thrust bearings. Duration: 2 hrs Objectives: Basic Concepts Describe two general categories of sliding surface bearings. Describe common types of journal bearings. Describe common types of t hrust bearings. Describe the process of film lubrication. Describe ways t hat sliding surface bearings can be lubricated. Performance Describe common indications of bearing performance. Describe inst ruments that can be used to measure indicat ions of bearing performance. Describe common causes of sliding surface bearing failure. Maintenance Describe a procedure for disassembling a journal bearing. Describe what to look for during an inspection of a disassembled journal bearing. Describe how to check the total clearance bet ween a journal bearing and a shaft. Describe a procedure for reassembling a journal bearing. Describe how to take a thrust reading. Describe a procedure for disassembling a thrust bearing. Describe what to look for during the inspection of a disassembled thrust bearing. Describe a procedure for reassembling a thrust bearing.
Subjects: Basic Concepts Types Lubrication Performance Performance Indications Types of Failure Maintenance Journal Bearing Thrust Bearing Course 103 of 245
Maintenance
CIRCUIT BREAKERS: Breakers and Switchgear 1 (IHRDC_OM_AECLV)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion and maintenance of low voltage circuit breakers and switchgear. After completing this unit, trainees should be able to describe the basic operation of a circuit breaker and t he basic functions of switchgear. They should be able to explain how an arc forms and how arcs can be extinguished, and also describe basic procedures for racking out a circuit breaker and performing maintenance and testing on it . Duration: 2 hrs Objectives: Basic Operation Describe how an electromagnet ic t rip device operates in a typical circuit breaker. Describe how a thermal element t rip device operates in a typical circuit breaker. Describe how a dashpot can be used to delay the movement of a trip device. Describe ways in which circuit breaker contacts can be closed. Describe the functions of three sections of a t ypical switchgear assembly. Describe how a typical circuit breaker is connected t o primary power and control power. Principles of Circuit Interruption Describe what an arc is and how it forms. Describe how speed, distance, and cooling affect ext inguishing an arc. Describe how a metal fin arc chute can be used t o extinguish an arc in a typical circuit breaker. Explain what current zero is. Maintenance Describe a procedure for racking a circuit breaker out for preventive maintenance. Describe a procedure for cleaning and inspect ing a typical circuit breaker as part of preventive maintenance. Describe how arc chutes and contacts are inspected and cleaned on a typical circuit breaker. Describe how to clean a typical circuit breaker during an overhaul. Describe how primary and secondary disconnect fingers are inspected on a t ypical circuit breaker. Describe how to lubricate t he moving parts in the operating mechanism of a t ypical circuit breaker. Describe three checks that can be performed on t he movable and stationary contacts of a typical circuit breaker. Describe how to perform an instantaneous trip test and a t ime delay trip test on a typical circuit breaker.
Subjects: Basic Operation Circuit Breakers Switchgear Principles of Circuit Interruption Arcs Extinguishing an Arc Maintenance Prevent ive Maintenance Overhaul Test ing Course 104 of 245
Maintenance
CIRCUIT BREAKERS: Breakers and Switchgear 2 (IHRDC_OM_AECHV)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion and maintenance of high voltage breakers and switchgear. After completing this unit, trainees should be able to describe the basic operation of an air-magnetic circuit breaker and an oil circuit breaker. They should also be able to explain how each type of circuit breaker extinguishes an arc, and describe basic procedures for racking out high voltage circuit breakers and performing maintenance and testing on t hem. Duration: 2 hrs Objectives: Principles of Operation Describe the main components of a t ypical air-magnet ic circuit breaker. Describe how an arc is extinguished in a t ypical air-magnet ic circuit breaker. Describe the main components of a t ypical oil circuit breaker. Describe how an arc is extinguished in a t ypical oil circuit breaker. Describe a typical undervoltage and overvoltage protection system used with high voltage circuit breakers. Maintenance of Air-Magnetic Circuit Breakers Describe one way to disconnect an air-magnet ic circuit breaker from power. Describe how to inspect the interior of an empty switchgear cell. Describe how to inspect the arc chut es and arc runners on a t ypical air-magnet ic circuit breaker. Describe how to inspect and clean the st at ionary and movable cont acts on a t ypical air-magnet ic circuit breaker. Describe how to inspect the operating mechanism and the primary and secondary disconnects on a typical air-magnetic circuit breaker. Describe how to perform elect rical test s on a typical air-magnetic circuit breaker. Maintenance of Oil Circuit Breakers Describe a procedure for electrically isolating a t ypical oil circuit breaker. Explain why an oil sample is typically taken from an oil circuit breaker before maintenance is performed. Describe a procedure for disassembling a typical oil circuit breaker. Describe how the contact s and the operating mechanism are maintained on a typical disassembled oil circuit breaker. Describe a procedure for reassembling a typical oil circuit breaker.
Subjects: Principles of Operation Air-Magnetic Circuit Breakers Oil Circuit Breakers Circuit Protection Maintenance of Air-Magnetic Circuit Breakers Preparations Inspection and Cleaning Electrical Tests Maintenance of Oil Circuit Breakers Preparations Inspection, Cleaning, and Reassembly Course 105 of 245
Maintenance
COMPRESSORS: Centrifugal (IHRDC_OM_AMCCC)
Overview: This interactive training unit is designed to explain centrifugal compressor components and operat ion. It also covers disassembly and reassembly of a vertically split compressor and the various checks and measurements t hat are made t o compressor components. Duration: 2 hrs Objectives: Introduction Describe the operation of a centrifugal compressor. Ident ify the component s of a horizontally split centrifugal compressor. Ident ify the component s of a vertically split centrifugal compressor. Describe the main components of a compressor lubrication system. Define surging. Compressor Overhaul Describe some common precautions and preparations associated with centrifugal compressor maint enance. Describe one way to remove int ercoolers, diffusers, impellers, diffuser covers, and pinion shaft assemblies from a vertically split cent rifugal compressor. Describe some common checks and measurements that are made during a compressor overhaul. Describe a procedure for reassembling a vertically split centrifugal compressor.
Subjects: Introduction Components and Operation Support Systems Compressor Overhaul Maintenance Practices Disassembly Component Inspection Reassembly Course 106 of 245
Maintenance
COMPRESSORS: Reciprocating (IHRDC_OM_AMCAC)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion and maintenance of reciprocating compressors. Aft er completing t his unit, trainees should be able t o identify the main components of a reciprocating compressor, explain how the compressor operates, and describe routine maintenance tasks that are commonly performed on reciprocating compressors. They should also be able t o describe tasks generally associated with a compressor overhaul. Duration: 2 hrs Objectives: Compressor Basics Ident ify the main components of a reciprocating air compressor. Describe the general operation of a reciprocating air compressor. Describe factors that determine air compressor design. Describe components t hat are part of lubrication, air flow, cooling, and moisture removal systems in a typical reciprocating air compressor. Describe tasks rout inely performed to maintain the efficiency of a reciprocat ing air compressor. Overhaul Ident ify and describe components of a reciprocating air compressor that are removed during compressor disassembly. Describe a procedure for disassembling a reciprocat ing air compressor. Describe a procedure for cleaning and inspect ing int ernal components of a reciprocating air compressor. Describe a procedure for reassembling a reciprocating air compressor.
Subjects: Compressor Basics Components and Operation Rout ine Maintenance Overhaul Disassembly Cleaning and Inspection Reassembly Course 107 of 245
Maintenance
DIAGRAMS: Blueprints (IHRDC_OM_AEDBL)
Overview: This interactive training unit introduces the basic features of const ruction blueprints. Aft er completing t his unit, trainees should be able to describe various types of blueprint s; identify lines, symbols, and abbreviations that are commonly found in blueprints; and explain how to properly care for blueprints.
Duration: 2 hrs Objectives: Introduction Describe what a blueprint is, and identify some of t he methods used to create blueprints. Ident ify two basic types of drawings that can be used to illustrat e objects on paper. Describe the t ypes of drawings typically included in a set of blueprints: Working Drawings (plan views, elevation drawings, section drawings, detail drawings) Auxiliary Drawings (electrical plans, HVAC plans, plumbing plans, door and window schedules, framing plans) Describe the basic elements of a blueprint, including the design drawing area, title block, revision block, legend and scale. Scales and Symbols Describe the Engineer's, Archit ect's and Met ric scales commonly used as measuring tools for blueprint s. Describe the following types of lines commonly used on blueprints: Property lines Boundary lines Main object lines Hidden lines Center lines Dimension and extension lines Break lines Section lines Reference lines for sections Leader lines Ident ify examples of building mat erial symbols, electrical symbols, plumbing and piping symbols and door and window symbols commonly used on blueprints. Ident ify abbreviations commonly used on blueprints. Using Blueprints Describe how dimensions are used on blueprints t o show sizes and distances. Ident ify rules for protecting blueprint s during their use.
Subjects: Introduction What is a Blueprint? Working Drawings Parts of a Blueprint Scales and Symbols Types of Scales Line Scales Symbols Abbreviations Using Blueprints Dimensions Care of Blueprints Course 108 of 245
Maintenance
DIAGRAMS: Electrical (IHRDC_OM_AEDEL)
Overview: This interactive training unit is designed to familiarize trainees wit h various types of electrical diagrams. After completing this unit, trainees should be able t o explain why symbols are used on electrical diagrams, and how to obtain informat ion from a title block and an equipment location index. They should also be able to explain how to use each of the following t ypes of diagrams: block, single line, schematic, wiring, connection, interconnection, and raceway. Duration: 2 hrs Objectives: Diagram Basics Explain why symbols are used on electrical diagrams. State the purpose of the American Standard Device Function Numbers Table and the Standard Diagram Abbreviations Table. State the purpose of legends on electrical diagrams. Describe information commonly found in title blocks on electrical diagrams. State the purpose of notes on electrical diagrams. Define equipment locat ion index. Describe how to use an equipment location index. Types of Diagrams State the purpose of a block diagram. State the purpose of a single line diagram. Ident ify symbols commonly used on single line diagrams. Describe information that can be found on single line diagrams. State the purpose of a schematic diagram. Describe how to read a schematic diagram. State the purpose of a wiring diagram. Describe how to use a wiring diagram to locate components. State the purpose of a connection diagram. Describe how to read a connect ion diagram. State the purpose of an interconnection diagram. Describe how to read an interconnection diagram. State the purpose of a raceway diagram. Describe how to read a raceway diagram. Explain how to use Raceway Not es, Symbols, and Det ail Reference, and a Raceway Schedule.
Subjects: Diagram Basics Symbols Title Blocks Equipment Location Index Types of Diagrams Block Diagrams Single Line Diagrams Schematic Diagrams Wiring Diagrams Connection Diagrams Raceway Diagrams Course 109 of 245
Maintenance
DIAGRAMS: Industrial Process Systems (IHRDC_OM_AEDPR)
Overview: This interactive training unit is designed to int roduce trainees to plant system diagrams and diagram symbols. After completing t his unit, trainees should be able t o identify and describe the purpose of several kinds of system diagrams, and describe the information found on each type. Trainees should also be able to identify symbols commonly used on piping and instrumentation diagrams (P&IDs), describe the types of informat ion typically found on a legend, and use a P&ID to locat e the component s of a system. Duration: 2 hrs Objectives: Types of Diagrams Ident ify and describe the purpose of equipment arrangement diagrams, elevation drawings, piping system (flow) diagrams, piping and instrument at ion diagrams (P&IDs), electrical diagrams, and legends. Describe, in general t erms, the information found on each t ype of diagram. Flow Diagram Symbols Ident ify some of the basic symbols associated wit h flow diagrams. Ident ify symbols commonly used t o represent components in flow diagrams. Briefly describe the basic operat ion of the components typically found in a fluid system. Piping and Instrumentation Diagrams Ident ify instruments using an identification chart. Ident ify line symbols and instrument symbols used in piping and instrumentation diagrams. Using a System Diagram Describe the t ypes of information typically found on a legend. Locate the components in a boiler fuel oil system by identifying the symbols used to represent them.
Subjects: Types of Diagrams Equipment Location Diagrams System Diagrams Flow Diagram Symbols Tanks, Pumps, and Valves Actuators Heat Exchangers Using a System Diagram Legends Using a System Diagram Course 110 of 245
Maintenance
ELECTRIC MOTORS: AC Motor Controllers 1 (IHRDC_OM_AEEA1)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic funct ions and operation of AC motor controllers. Aft er completing t his unit, trainees should be able t o explain how an AC motor controller operates and describe the operation of master switches and pilot devices that can be used with AC motor controllers. They should also be able to explain how an AC motor can provide overload protection and low voltage protection, and to describe the operation of special types of AC motor controllers. Duration: 2 hrs Objectives: Introduction Describe how a manual controller can be used t o control a mot or. Describe how a magnetic controller can be used to control a motor. Describe the parts and operation of a typical magnetic contactor. Describe the operation of a magnetic contactor in a t ypical AC motor cont roller. Describe the operation of maintaining master switches and momentary master switches. Describe the operation of float switches, pressure switches, limit switches, and flow switches. Describe the operation of bellows thermostats and bimetallic strip thermost at s. Explain how a mercury switch can be used in a pilot device. Protective Devices State the purpose of overload devices. Describe the parts and operation of t wo types of thermal overload devices. Describe the parts and operation of a typical magnetic overload device. State the purpose of low voltage protection in a magnetic mot or controller. Describe the operation of an LVP and an LVR motor cont roller. Explain how a low voltage relay operates. Special Motor Controllers Explain how a reduced voltage start motor controller provides protect ion to motors when they are first start ed. Describe the operation of a two-speed and a reversible motor controller.
Subjects: Introduction Basic Principles Contactors Master Switches and Pilot Devices Protective Devices Overload Prot ection Low Voltage Prot ection Special Motor Controllers Reduced Voltage Start Two-Speed Reversible Course 111 of 245
Maintenance
ELECTRIC MOTORS: AC Motor Controllers 2 (IHRDC_OM_AEEA2)
Overview: This interactive training unit is designed to familiarize trainees wit h basic procedures for troubleshooting and maint aining AC motor controllers. Aft er completing t his unit, trainees should be able t o use diagrams and charts to obtain information about an AC motor controller. They should also be able to explain how t o troubleshoot a problem in an AC motor controller and how t o inspect and clean a controller's part s. Duration: 2 hrs Objectives: Introduction Explain how to use a schematic diagram to obtain informat ion about the operation of an AC motor cont roller. Explain how to use a wiring diagram to locate t he components in an AC motor controller. Describe a typical legend and a typical sequencing chart. Describe a basic procedure for troubleshooting an AC motor cont roller. Ident ify and describe typical sources of information about the normal operat ion of an AC motor controller. Ident ify and describe possible sources of informat ion about an AC motor controller malfunction. Describe how to use a schematic diagram to diagnose an AC motor controller malfunction. Troubleshooting Describe how a voltage tester can be used to locate a malfunction in an energized AC motor controller. Describe how to test an AC motor cont roller to determine if it is de-energized. Describe how a megohmmeter can be used to test a de-energized AC motor controller for grounds. Describe how a multimeter can be used to locate an open and a short in a de-energized AC mot or controller. Maintenance Explain why an AC motor controller should be kept clean. Describe how an AC motor controller can be cleaned. Describe a basic procedure for inspecting an AC motor cont roller's magnetic contactor. Describe how to inspect an AC motor controller's wiring and components.
Subjects: Introduction Diagrams and Charts Procedures Troubleshooting Energized Controllers De-Energized Controllers Maintenance Cleaning Inspection Course 112 of 245
Maintenance
ELECTRIC MOTORS: DC Motors (IHRDC_OM_AEEDM)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion and maintenance of DC motors. After completing this unit, t rainees should be able to describe the operation and basic parts of a DC mot or. They should also be able t o describe basic procedures for maintaining and overhauling a DC mot or. Duration: 2 hrs Objectives: Motor Principles Explain what motor action is. Describe armature reaction in DC motors. Ident ify the basic parts of a DC motor. Explain how DC motors can be classified. Motor Maintenance Describe problems that can occur with the brushes in a DC mot or. Describe the characteristics of a good brush. Explain how to inspect and replace brushes in a DC motor. Describe how a commutator can be cleaned. Describe typical commutator problems. Describe a basic procedure for troubleshooting a DC motor's armature and field windings and their connect ions. Describe how to test for grounds, opens, and shorts in a DC motor. Motor Overhaul Describe how to disassemble a DC motor. Describe how to inspect and clean a disassembled DC motor. Describe how to reassemble a DC motor.
Subjects: Motor Principles Motor Action DC Mot ors Motor Maintenance Brushes and Brush Rigging Commutators Troubleshooting Motor Overhaul Disassembly Inspection and Cleaning Reassembly Course 113 of 245
Maintenance
ELECTRIC MOTORS: Motor Branch Circuit Protection (IHRDC_OM_AEEMB)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion and maintenance of motor branch circuits. After completing this unit, trainees should be able to describe the component s of a typical motor branch circuit, preventive maintenance procedures, and one way to troubleshoot a problem in a motor branch circuit. Duration: 2 hrs Objectives: Motor Branch Circuits Describe a typical mot or branch circuit. Ident ify and describe protect ion devices typically used in motor branch circuits. Describe a procedure for overriding a safety switch enclosure interlock. Describe general charact eristics of fuses commonly used in motor branch circuits. Describe how to determine what size fuse to use when the proper fuse rating for a motor branch circuit is unknown. Describe a typical molded-case circuit breaker and explain how it can be reset. Describe the operation of thermal, magnetic, and thermal-magnetic molded-case circuit breakers. Maintenance Describe a low-impedance grounding syst em t ypically used wit h motor branch circuit s and explain how it can be maintained. Describe a general preventive maintenance procedure for a motor branch circuit. Describe one way to troubleshoot a mot or branch circuit.
Subjects: Motor Branch Circuits Circuits Safety Swit ches Circuit Breakers Maintenance Prevent ive Maintenance Troubleshooting Course 114 of 245
Maintenance
ELECTRIC MOTORS: Three Phase (IHRDC_OM_AEETP)
Overview: This interactive training unit is designed to familiarize trainees wit h three-phase AC motor operation, inspect ion, testing, and maintenance. After completing this unit , trainees should be able to explain the basic principles of three-phase AC motor operation, how to inspect one, and how to conduct electrical t ests on one. They should also be able t o explain how to disconnect, disassemble, clean, reassemble, and reconnect a three-phase AC motor. Duration: 2 hrs Objectives: Motor Principles Describe alternating current. Explain the relationship bet ween the three phases of three-phase alternating current . Ident ify the basic parts of a three-phase AC motor. Ident ify and describe common types of three-phase AC mot ors. Describe the operation of a typical three-phase AC motor. Explain what slip is, and describe the effects of increasing load on an AC mot or. Describe how speed control can be accomplished in a t hree-phase AC motor. Inspection and Testing Describe how an operating and non-operating three-phase AC motor can be inspected. Explain the purpose of an insulation test and describe how it can be conducted on a three-phase AC mot or. Describe how to test for grounds in the stator of a three-phase AC motor. Describe how to test for opens in a wye-connected stator of a three-phase AC motor. Describe how to test for opens in a delta-connect ed stator of a three-phase AC mot or. Describe how to test for shorts in the stator of a three-phase AC mot or. Describe how to test for grounds, opens, and shorts in the rotor circuit of a wound three-phase AC mot or. Motor Maintenance Describe how to disconnect and disassemble a three-phase AC mot or. Describe how to inspect and clean a disassembled three-phase AC motor. Describe how to reassemble and reconnect a three-phase AC motor.
Subjects: Motor Principles AC Review Three-Phase AC Motors Speed Control Inspection and Testing Motor Inspection Insulation Testing Stator Testing Rotor Testing Motor Maintenance Disconnection and Disassembly Inspection and Cleaning Reassembly and Reconnect ion Course 115 of 245
Maintenance
ELECTRICAL MAINTENANCE: Battery Systems (IHRDC_OM_AEETM)
Overview: This interactive training unit is designed to int roduce trainees to industrial battery systems, and bat tery cells, and how to inspect and test batteries. After complet ing this unit, trainees should know the characteristics and baic operat ion of a typical battery system and its components. They should also underst and how to inspect and perform basic tests on industrial bat teries. Duration: 2 hrs Objectives: Introduction to Battery Systems Describe a typical industrial battery system. List the basic components of a lead-acid cell. Describe the electrochemical action in a cell that is charging. Describe the electrochemical action in a cell that is discharging. State the voltage rating for a t ypical cell at full charge. Explain a cell's capacity rat ing. Briefly describe the relationship of cell capacity, voltage, and specific gravity during discharge and recharge. Describe the functions of a typical battery system charger. List the common components of most bat tery chargers and describe their functions. Inspection and Testing List the prot ective equipment and safety procedures associated with working on batt eries. Describe typical visual inspection checks. State the purpose of and describe t he basic steps for checking intercell and terminal connection resistances. State the purpose of and describe t he basic steps for checking specific gravity. Explain the effect of temperature on specific gravity.
Subjects: Introduction to Battery Systems System Overview Cell Components Cell and Batt ery Ratings Battery Chargers Inspection and Testing Battery System Safety Battery Inspection Volt age and Resist ance Testing Specific Gravity Test ing Course 116 of 245
Maintenance
ELECTRICAL MAINTENANCE: Fasteners (IHRDC_OM_AEEFA)
Overview: This interactive training unit is designed to familiarize trainees wit h various types of fasteners used in electrical work. After completing this unit, t he trainees should be able to describe common types of threaded and non-threaded fast eners and identify applications for which each type might be used. They should also be able to describe basic procedures for installing fasteners. Duration: 2 hrs Objectives: Types of Fasteners Describe some common types of threaded fasteners and identify applications for which these fasteners may be used. Describe some common types of non-threaded fasteners and identify applicat ions for which these fasteners may be used. Installing Fasteners Describe general steps for inst alling threaded fasteners. Describe a typical procedure for installing a toggle bolt. Describe a typical procedure for installing an anchor bolt in wet concrete. Describe a typical procedure for installing an expansion anchor bolt in hardened concrete. Describe a typical procedure for installing blind rivets.
Subjects: Types of Fasteners Threaded Fasteners Non-Threaded Fasteners Installing Fasteners Basic Steps Installing Toggle Bolts Installing Anchor Bolts Installing Blind Rivets Course 117 of 245
Maintenance
ELECTRICAL MAINTENANCE: Introduction to the NEC (IHRDC_OM_AEEIN)
Overview: This interactive training unit is designed to familiarize trainees wit h the organizat ion and layout of the National Elect rical Code. Aft er completing t his unit, the trainees should be able to use the NEC to locate specific types of information. Duration: 2 hrs Objectives: Overview Explain the purpose and describe the history of t he NEC. Describe how the NEC was developed and revised. Describe the role of testing laboratories in developing the NEC. Describe the purpose of the NFPA and the NEMA. Explain the difference between mandatory rules and advisory rules. Describe the kinds of informat ion found in Articles 90, 100, and 110 of the NEC. Define t he terms labeled and listed. Describe how the chapters of the NEC are organized. Describe the different types of text used in the NEC. Using the NEC Explain how to locate information for a particular procedure in the NEC. Ident ify and describe key sections of the NEC that are often used as references for servicing elect rical systems. Describe how the NEC can be used as a reference for installing elect rical systems.
Subjects: Overview Purpose and History Layout Using the NEC Navigating Examples Course 118 of 245
Maintenance
ELECTRICAL MAINTENANCE: Relays 1 (IHRDC_OM_TDRE1)
Overview: The purpose of this unit is to t each the basic principles of protect ive relays and to introduce directional and nondirectional relays. The unit begins with t he basic theory of protective relays, commonly used types of relays, and a brief explanation of how t hese relays are used. Additional det ails and examples are provided for directional and nondirectional relays. At the conclusion of this unit , the trainees should have a basic understanding of how protective relays work. They should be able to explain the need for protective relays and to list commonly used types of relays and their functions. They should also be able to explain how directional and nondirect ional relays work and give examples of how they are used. Duration: 2 hrs Objectives: Introduction to relays Explain the purpose of protective relays in a T&D system and describe how they are used. Describe five common relay elements and how they work. Overcurrent relays Describe the basic operating principles of overcurrent relays and the condit ions that cause them to operate. Directional overcurrent relays Ident ify T&D equipment typically protected by directional overcurrent relays. Describe the basic operating principles of directional overcurrent relays and the conditions that cause them to operate. Reclosing relays Describe the basic function and operating principles of reclosing relays. Voltage relays Ident ify the type of equipment that volt age relays t ypically protect. Describe the basic operating principles of voltage relays and the conditions t hat cause t hem to operat e. Auxiliary relays Describe the basic function and operatiing principles of auxiliary relays. Solid-state relays Describe the basic operating principles of solid-state relays. Define t he terms analog signal , digit al signal and logic circuit .
Subjects: Introduction to relays Purpose and use of relays Relay elements: plunger element, clapper element, induct ion disc element , induction cup element and solid-state circuitry. Overcurrent relays: Instantaneous overcurrent relays; time-delay overcurrent relays Directional overcurrent relays: Usage and operation; three-phase directional relays Reclosing relays: function, components and operat ion Voltage relays Overvoltage and undervolt age relays with plunger elements; overvoltage relay with an induction disc element; overvoltage/undervoltage relay Auxiliary relays Function of auxiliary relays Auxiliary relay used t o trip multiple breakers Auxiliary relay used t o trip multiple overcurrent relays Solid-state relays Operating principles of solid state relays; Logic gates Course 119 of 245
Maintenance
ELECTRICAL MAINTENANCE: Relays 2 (IHRDC_OM_TDRE2)
Overview: This unit continues the development begun in Relays 1 by introducing differential and pilot relays and discussing routine relay maintenance. At the conclusion of this unit, trainees should be able to explain how differential and pilot relays work and give examples of situations where they are used. They should also be able to describe how to approach routine inspection and maintenance and how to put a relay in or out of service. Duration: 2 hrs Objectives: Introduction to relays Ident ify five common relay elements. Describe t he funct ions of overcurrent , direct ional overcurrent, reclosing, voltage, and auxiliary relays. Differential relays Ident ify what different ial relays typically protect. Describe t he basic operating principles of different ial relays and t he condition that causes a differential relay t o operate. Transfer tripping Describe the function of a transfer tripping system and identify its main components. Ident ify four communication channels used for transfer tripping and explain how they work. Ident ify the main equipment components associated with transfer tripping communication channels and describe their funct ions. Distance relays Ident ify what distance relays t ypically protect. Describe the basic operating principles of distance relays and the condition t hat causes a distance relay to operate. Pilot wire relaying Describe the function of a pilot wire relaying system. Ident ify the main components of a pilot wire relaying system and describe its basic operating principles. Breaker failure relaying Ident ify the function and the main components of a breaker failure relaying system. Describe the general operation of a breaker failure relaying system. Describe the basic operating principles of (1) a breaker failure relay and (2) a timing relay in a breaker failure relaying system.
Subjects: Introduction to relays Relay elements (plunger element, clapper element, iInduction disc element, induction cup element and solid-state circuitry) Basic protect ive relay functions (overcurrent relays, directional overcurrent relays, reclosing relays, volt age relays and auxiliary relays) Differential relays Different ial relay operation; current backfeed and different ial relay operation; types Transfer tripping Function of transfer tripping; transfer tripping example; communication channels and equipment Distance relays Function of distance relays; zoned protection; construction and operation of a dist ance relay Pilot wire relaying Pilot wire relaying system components and operation; pilot wire relay component s and operation Breaker failure relaying system components and operation Timing relay components and operation Course 120 of 245
Maintenance
ELECTRICAL MAINTENANCE: Troubleshooting Electrical Circuits (IHRDC_OM_AEETA)
Overview: This interactive training unit is designed to familiarize trainees wit h the use of basic troubleshooting procedures to troubleshoot problems in electrical circuits. After completing this unit, trainees should be able to identify and describe the mainsteps of a basic troubleshooting procedure and use t he procedure to t roubleshoot problems in elect rical equipments and electrical systems. Duration: 2 hrs Objectives: Troubleshooting Fundamentals Explain what troubleshooting is. Ident ify and describe the main steps of a basic t roubleshooting procedure. Describe how electrical tests can be used in the process of eliminat ion. Describe two basic ways that the process of elimination can be used in t roubleshooting. Troubleshooting Examples Describe how to troubleshoot a problem in a piece of electrical equipment. Describe how to troubleshoot a problem in an electrical system.
Subjects: Troubleshooting Fundamentals What is Troubleshooting? The Process of Elimination Troubleshooting Examples Electrical Equipment Electrical Systems Course 121 of 245
Maintenance
ELECTRICAL THEORY: AC Circuits (IHRDC_OM_AEEAC)
Overview: This interactive training unit is designed to familiarize trainees wit h basic concepts associated with the operation of AC circuits. Aft er completing t his unit, trainees should be able t o explain how current flows t hrough AC circuit s and how AC current and voltage are affected by inductance and capacitance. They should also be able to define t rue power, reactive power, apparent power, and power factor, and to identify various types of single-phase and three-phase systems. Duration: 2 hrs Objectives: Alternating Current Explain the difference between direct current and alternating current. Explain how current flow and polarity change in AC circuits. Describe a sine wave t hat represents AC voltage. Explain what frequency is, and how it is measured. Define peak value, peak-to-peak value, and effective value with respect to AC voltage and current. Inductance Define inductance and inductive react ance. Explain how inductive reactance limits current flow. Explain how the inductive reactance in a circuit can be increased. Describe the effects of induct ance on current and voltage. Capacitance Define capacitance and capacitive react ance. Explain how a capacit or is charged. Describe the effects of capacit ance on current and voltage. AC Power Different iate between true power, reactive power, and apparent power. Explain how power factor is used in calculating true power in AC circuits. Explain how a three-wire single-phase AC system supplies two different voltages. Different iate between delta-connected and wye-connect ed three-phase AC systems.
Subjects: Alternating Current Current Flow Sine Waves Peak Values and Effective Values Inductance Inductance and Induct ive Reactance Factors That Affect Inductive React ance Inductance, Current, and Voltage Capacitance Capacitance and Capacitive Reactance Capacitance, Current and Voltage AC Power True Power, Reactive Power, and Apparent Power Single Phase and Three-Phase Systems Course 122 of 245
Maintenance
ELECTRICAL THEORY: Basic Electricity Review (IHRDC_OM_AEBER)
Overview: This interactive training unit is designed to familiarize trainees wit h some of the basic principles associat ed with electricity and electrical circuits. Aft er completing t his unit, trainees should be able t o explain where electricity comes from; what voltage, current, and resistance are; and how their values can be calculated for various types of circuits. They should also be able t o explain how electrical circuits are affected by induct ion, inductance, and capacitance. Duration: 2 hrs Objectives: Basic Concepts Explain what atoms are, and how they are constructed. Explain what voltage is, and how it can be produced. Explain what current is, and state t he basic difference bet ween direct current and alt ernating current. Explain what resistance is, and st at e the basic difference between a conductor and an insulat or. Explain how volt age, current, and resistance can be measured. Explain what power and elect rical energy are and how they can be measured. Explain how Ohm's Law relates to current , voltage, and resistance. Explain how to use Ohm's Law to calculate current, voltage, or resistance when the other two values are known. Circuit Types Describe the basic operating principles of a series circuit. Explain how to calculate values for current, voltage, and resistance in a series circuit. Describe the basic operating principles of a parallel circuit. Explain how to calculate values for current, voltage, and resistance in a parallel circuit. Describe the basic operating principles of a series-parallel circuit . Explain how to calculate values for current, voltage, and resistance in a series-parallel circuit. Circuit Characteristics Explain what induction is and how voltage can be induced in a conduct or. Describe the basic operation of a transformer. Explain what inductance is and how it affects electrical circuits. Explain how the inductance of an induct or can be increased. Explain what capacitance is and how it affects electrical circuits. Describe the basic operation of a capacit or.
Subjects: Basic Concepts Where Does Electricit y Come From? Basic Electrical Quantities Ohm's Law Circuit Types Series Parallel Series-Parallel Circuit Characteristics Induction Inductance Capacitance Course 123 of 245
Maintenance
ELECTRICAL WIRING: Cables and Conductors (IHRDC_OM_AEECC)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic construction and installation of electrical cables and conductors. After completing this unit , trainees should be able to describe the basic const ruction of cables and conductors, and how conductors are classified and rated. They should also be able to describe factors that affect the installat ion of a conductor for a specific application, and how to make splices and terminations. Duration: 2 hrs Objectives: Basic Concepts Describe the basic construction of conductors. Describe how the physical characterist ics of a conductor's wires affect how the conduct or is classified and rated. Describe how the physical characterist ics of a conductor's insulation affect how the conductor is classified and rated. Installation Requirements Describe factors that determine the current requirements of a circuit. Describe factors that determine the voltage requirements of a circuit. Describe characteristics in an environment that affect t he type of conductor that should be installed. Explain how environmental temperatures affect t he type of conductor that should be installed. Electrical Connections Describe factors that should be considered when a mechanical connector is selected. Describe factors that should be considered when replacement insulat ion is selected. Describe how to make a splice. Describe how to make a termination.
Subjects: Basic Concepts Construction Classifications and Rat ings Installation Requirements The Circuit The Environment Electrical Connections Connectors and Replacement Insulation Splices and Terminations Course 124 of 245
Maintenance
ELECTRICAL WIRING: Conduit Installation (IHRDC_OM_AEECI)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic concepts of conduit and conduit fittings, and t ypical methods of cutting, bending, and installing conduit . After completing this unit, trainees should be able to describe the basic types of metallic and nonmetallic conduit, common types of conduit fittings, and procedures for cutting, bending, and installing met allic and nonmet allic conduit. Duration: 2 hrs Objectives: Materials Define t erms that are commonly used to describe conduit and conduit installations. Describe common types of metallic conduit . Describe common types of nonmetallic conduit . Fittings Describe types of couplings that are used t o connect conduit in a straight line. Describe types of fit tings t hat are used to change the direction of a conduit run. Describe types of fit tings t hat are used to secure conduit when it is installed. Cutting Describe a method for cutt ing rigid t ypes of met al conduit. Describe a method for cutt ing flexible types of metal conduit. Describe met hods for cutting nonmetallic conduit. Bending Describe different types of conduit bends and explain where they might be used in an installation. Explain how bends affect conduit measurements. Describe how rigid-type metal conduit can be bent. Describe how rigid PVC can be bent. Installing Describe tasks associated with t erminating conduit to an elect rical control box. Describe how conductors can be installed in conduit.
Subjects: Materials Overview Metallic Conduit Nonmetallic Conduit Fittings Making Straight Connections Changing Run Direction Securing Conduit Bending Bend Types Measurement s Demonstrations Installing Termination t o a Box Pulling Conductors Course 125 of 245
Maintenance
ELECTRICAL WIRING: Splices and Terminations (IHRDC_OM_AESAT)
Overview: This interactive training unit is designed to familiarize trainees wit h splices and terminations used in electrical systems of less than 600 volt s. After completing this unit, the t rainees should be able to identify basic types of electrical wiring, conductor terminals, and connect ors; describe tools and materials required to make conduct or splices and terminations; explain what makes a good electrical connection; describe common types of splices; and explain how to connect conductors to a terminal box on a 3-phase AC motor. Duration: 2 hrs Objectives: Hardware and Accessories Ident ify and describe basic types of elect rical wiring. Ident ify types of conductor terminals and connectors and describe the applications for which they are suitable. Ident ify and describe tools and materials typically used in making conductor splices and t erminations. Making Connections Ident ify the basic requirement s for a good electrical connection. Describe how to make some common types of splices and identify the applications for which each type of splice is suitable. Ident ify requirements for terminating conductors in enclosures. Describe how to make up connections to a terminal box on a 3-pnase AC mot or.
Subjects: Hardware and Accessories Types and Sizes of Conduct ors Terminals Solder Connect ors Solderless Connectors (Compression and Mechanical) Ring Terminal Spade (Fork) Terminal Quick Disconnect Terminals Butt Splice and Reducing Connect ors Compression Connector Variations Mechanical Connectors Dual-Rated Connectors Wire Connectors Strippers and Crimpers Solder and Soldering Tools Insulation (Tubing and Tapes) Cable Ties and Cable Clips Making Connections De-energizing Electrical Systems Stripping Insulation Selecting Connectors, Materials Common Splicing Methods (Western Union Splice, Rattail Joint, Fixture Joint , and Knott ed Tap Joint) Enclosures Motor Connect ions Course 126 of 245
Maintenance
FORKLIFTS: Operation (IHRDC_OM_AMFOO)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic design and operation of forklifts. Aft er completing t his unit, trainees should be able t o describe how forklift s can be classified and identify t he major features and common working dimensions of a forklift. They should also be able to explain how to inspect a forklift, how to recharge or refuel a forklift, and how t o operate a forklift safely. Duration: 2 hrs Objectives: Basics Describe ways in which forklifts can be classified and identify the t ypes of forklifts that are most appropriate for use in specific working conditions. Ident ify the major feat ures of most forklifts. Describe the common working dimensions of a forklift . Describe how to operate a typical forklift. Describe general safety considerations associated wit h forklift operation. Routine Tasks Describe tasks that are performed during typical forklift startup and prevent ive inspect ions. Describe basic procedures and safet y precautions associated wit h recharging elect ric forklifts and refueling forklifts that have internal combustion engines. Forklift Stability and Loads Explain the basic principles of forklift stabilit y and describe how they affect forklift operation. Describe general guidelines for handling loads safely with a forklift.
Subjects: Basics Types of Forklift s Major Features Basic Forklift Operation Forklift Traffic Safet y Routine Tasks Inspections Recharging and Refueling Forklift Stability and Loads Stability Handling Loads Course 127 of 245
Maintenance
GEARS: Overhauls (IHRDC_OM_AMGG1)
Overview: This interactive training unit is designed to explain major tasks involved in gearbox overhauls. Trainees learn about disassembly and reassembly procedures for two t ypes of gearboxes: a double action unit and a worm gear unit. Trainees will also learn t ypical checks and measurements performed during gearbox overhauls. Duration: 2 hrs Objectives: Disassembly and Reassembly Describe precautions associated with the disassembly of a double-reduction gearbox. Describe one way to remove the upper housing of a double-reduction gearbox. Describe how to remove the bearing endcaps and internal components of a double-reduction gearbox. Describe common methods of removing and installing a gear on its shaft. Describe precautions associated with gearbox reassembly. Describe the installat ion of the gears and endcaps in a typical double-reduction gearbox. Describe how to complete t he reassembly of a typical double-reduction gearbox. Ident ify differences in preparing a unit to be stored and preparing a unit t o be returned to service. Checks and Measurement Describe the procedure to check for shaft endplay. Describe the procedure to check for backlash and tooth contact. Describe the procedure to check for shaft runout. Worm Gearset Ident ify the main components of a motor actuator that uses a worm gearset. Describe one way to disassemble a worm gearbox. Describe one way to reassemble a worm gearbox. Explain how tooth contact checks are made on a worm gear arrangement.
Subjects: Disassembly and Reassembly Disassembly Gear Removal and Replacement Reassembly Checks and Measurements Endplay Backlash and Tooth Contact Shaft Runout Worm Gearsets Basic Component s Disassembly Reassembly Course 128 of 245
Maintenance
GEARS: Types and Characteristics (IHRDC_OM_AMGG2)
Overview: This interactive training unit is designed to int roduce trainees to gears and gear arrangements. After completing this unit , t rainees should know how a gearset basically works. They should be familiar wit h different types of gears and gear arrangements, and understand commonly used gear terminology. They should also be able to identify common gear problems. Duration: 2 hrs Objectives: Fundamentals Describe the function of gears. Describe how power, speed, and torque are involved in the operation of gears. Describe characteristics of spur gears. Describe characteristics of bevel gears. Describe characteristics of spiral bevel gears. Describe characteristics of helical gears. Describe characteristics of hypoid gears. Describe characteristics of worm gears. Define t he term backlash. Define t he term endplay. Define t he term t ooth cont act. Gearsets Ident ify the component s of a typical gearbox. Describe characteristics of a mechanical differential gearset arrangement. Gear Problems Ident ify some problems that can cause bearing failure. Describe gear tooth breakage and some condit ions that can cause it . Describe some gear lubricat ion problems. Describe how scoring affects gears. Describe how pitting affects gears.
Subjects: Fundamentals Speed and Torque Basic Types of Gears Worm Gears Backlash, Endplay, and Tooth Contact Gearsets Basic Gearbox Components Mechanical Differentials Gear Problems Bearing Failures Tooth Breakage Improper Lubrication Scoring and Pitting Course 129 of 245
Maintenance
HYDRAULICS: Actuators (IHRDC_OM_AHHAC)
Overview: This unit is designed to familiarize trainees with the operation of various types of cylinders and hydraulic motors in hydraulic systems. Aft er completing t his unit, trainees should be able t o describe the basic components and common types of singleacting cylinders and double-acting cylinders. They should also be able to describe the basic components and operation of common types of vane motors, gear motors, piston motors, and part ial rotation actuat ors. Duration: 2 hrs Objectives: Cylinders Describe the basic components and operation of a single-acting load-return cylinder. Describe the basic components and operation of a single-acting spring ret urn cylinder. Describe the basic components and operation of a telescoping cylinder. Describe the basic components and operation of a double-acting cylinder. Describe the basic components and operation of a double-rod cylinder. Describe the basic functions of piston rings, rod seals, rod wipers, and cylinder cushions. Describe how fixed and pivoting cylinder mountings can be used to mount linear actuat ors. Motors Describe the basic components and operation of a vane motor. Explain what a balanced vane motor is. Describe the basic components and operation of an external gear motor. Describe the basic components and operation of an internal gear mot or. Describe the basic components and operation of a gerotor motor. Describe the basic components and operation of an in-line piston motor. Describe the basic components and operation of a variable displacement in-line pist on motor. Describe the basic components and operation of a bent -axis piston mot or. Describe the basic components and operation of a vane type rotary actuator. Describe the basic components and operation of a crank type piston actuator. Describe the basic components and operation of a rack type piston actuator.
Subjects: Cylinders Single-Acting Double-Act ing Features Motors Vane Gear Pist on Partial Rotation Actuators Course 130 of 245
Maintenance
HYDRAULICS: Component Inspection and Replacement (IHRDC_OM_AHHCI)
Overview: This unit is designed to familiarize trainees with typical procedures for removing, inspecting, reassembling, and reinst alling hydraulic system components. After completing this unit, t rainees should be able to describe typical procedures for disassembling, inspecting, reconditioning, reassembling, and reinstalling valves, pumps, and cylinders. Duration: 2 hrs Objectives: Removal and Inspection Describe general precaut ions and preparations for safely removing and disassembling components from a hydraulic system. Describe typical procedures for disassembling and inspecting valves that are commonly used in hydraulic systems. Describe typical procedures for disassembling and inspecting a fixed displacement vane pump. Describe typical procedures for disassembling and inspecting a hydraulic cylinder. Reassembly and Reinstallation Describe general procedures for reassembling and reinst alling hydraulic system components. Describe typical procedures for reconditioning, reassembling, and reinstalling valves that are used in a hydraulic system Describe typical procedures for reconditioning and reassembling a fixed displacement vane pump. Describe typical procedures for reinstalling a pressure compensated, variable displacement piston pump. Describe typical procedures for reconditioning, reassembling, and reinstalling a hydraulic cylinder.
Subjects: Removal and Inspection Basic Preparations Valve Inspection Pump Inspection Cylinder Inspection Reassembly and Reinstallation General Guidelines Valve Reconditioning and Reinst allation Pump Reconditioning and Reinst allation Cylinder Reconditioning and Reinst allation Course 131 of 245
Maintenance
HYDRAULICS: Diagrams (IHRDC_OM_AHHDI)
Overview: This unit is designed to familiarize trainees with hydraulic system schemat ic diagrams. After completing this unit, trainees should be able to interpret symbols that are used in hydraulic system schemat ic diagrams and use schematic diagrams t o trace fluid flow t hrough various t ypes of hydraulic circuits. Duration: 2 hrs Objectives: Symbols Ident ify symbols used to represent the basic parts of a hydraulic circuit. Ident ify types of lines represented on a hydraulic schematic diagram. Ident ify symbols used to represent the following pumps: unidirectional fixed displacement, bi-directional fixed displacement, unidirectional variable displacement, bi-directional variable displacement. Ident ify symbols used to represent the following component s: reservoirs, accumulators, heat ers, coolers, and filters. Ident ify symbols used to represent the following linear actuators: single-act ing, double-act ing, fixed cushion cylinder and adjustable cushion. Ident ify symbols used to represent the following hydraulic motors: unidirectional, fixed displacement, bi-directional, fixed displacement, unidirectional, variable displacement, bi-directional, variable displacement. Ident ify symbols used to represent the following valves: pressure relief valve, flow control valve, and directional cont rol valve. Reading Diagrams Describe basic guidelines for reading hydraulic schematic diagrams. Use a schemat ic diagram to describe how fluid flows through an automatic venting circuit . Use a schemat ic diagram to describe how fluid flows though an accumulator circuit. Use a schemat ic diagram to describe how fluid flows through a regenerat ive circuit.
Subjects: Symbols Overview Pumps Fluid Storage and Fluid Containers Actuators Valves Reading Diagrams Diagram Reading Basics Automat ic Venting Circuit Accumulator Circuit Regenerative Circuit Course 132 of 245
Maintenance
HYDRAULICS: Fluid and Reservoirs (IHRDC_OM_AHHFS)
Overview: This unit is designed to familiarize trainees with the fluid used in hydraulic systems and with the basic functions and uses of filt ers and st rainers, reservoirs, conduct ors, and accumulators. After completing this unit, trainees should be able to describe the functions, characteristics, and types of fluid that may be used in hydraulic systems. They should also be able to describe typical uses of filt ers and strainers, the components and accessories of typical reservoirs, the various types of conductors and fit tings, and t he basic functions and common uses of accumulat ors in hydraulic syst ems. Duration: 2 hrs Objectives: Hydraulic Fluid Describe the functions of the fluid in a hydraulic syst em. Describe properties that are considered when hydraulic fluid is selected for a specific application. Describe the basic charact eristics of various types of hydraulic fluid. Explain how filt ers and strainers can be classified. Describe typical uses of strainers and filters in hydraulic systems. Reservoirs and Conductors State the function of a reservoir in a hydraulic system. Describe the components and accessories of a t ypical hydraulic fluid reservoir. Describe various types of heat exchangers that may be used wit h hydraulic fluid reservoirs. Describe types of conductors and fittings that are used in hydraulic systems. Accumulators Describe the basic function and common uses of accumulators in hydraulic systems. Describe the components and operat ion of various types of accumulators.
Subjects: Hydraulic Fluid Types of Fluid Filters and St rainers Reservoirs and Conductors Reservoirs Conductors Accumulators Function and Applications Types of Accumulators Course 133 of 245
Maintenance
HYDRAULICS: Principles and Circuits (IHRDC_OM_AHHPC)
Overview: This unit is designed to familiarize trainees with the principles of hydraulic system operation and the components and operation of some typical hydraulic circuits. Aft er completing t his unit, trainees should be able t o explain how force is transmitt ed through a liquid and how pressure and flow are related in a hydraulic system. They should also be able to describe the main concepts and basic operation of several t ypes of hydraulic circuits. Duration: 2 hrs Objectives: Principles Explain what a liquid is and how liquids differ from solids and gases. Explain how force is transmitted through a liquid. Define t he following terms: pressure, head, atmospheric pressure, vacuum, laminar flow, turbulent flow, velocity, and flow rate. Describe the relationship bet ween pressure and flow in a hydraulic system. Circuits List the main components of a basic hydraulic circuit and describe t he funct ion of each component. Describe the basic operation of an automat ic vent ing circuit. Describe the basic operation of an accumulator circuit. Describe the basic operation of a regenerative circuit.
Subjects: Principles Charact eristics of Liquids Pressure and Flow Circuits Circuit Component s Typical Hydraulic Circuits Course 134 of 245
Maintenance
HYDRAULICS: Pumps (IHRDC_OM_AHHPU)
Overview: This unit is designed to familiarize trainees with the operation of various types of pumps in hydraulic systems. After completing t his unit, trainees should be able t o describe the basic operation of common types of gear pumps, vane pumps, radial piston pumps, axial piston pumps, and pressure compensated piston pumps. Duration: 2 hrs Objectives: Types of Pumps Describe the basic operation of a hydraulic power circuit . Describe the role of a pump in a typical hydraulic power circuit. Describe how positive displacement pumps work and explain why they are used in hydraulic power circuits. Describe the differences between a fixed displacement pump and a variable displacement pump. Rotary Pumps Describe the basic operation of an external gear pump. Describe the basic operation of an internal gear pump. Describe the basic operation of a gerotor pump. Describe the basic operation of an unbalanced vane pump. Describe the basic operation of a pressure compensated vane pump. Describe the basic operation of a balanced vane pump. Piston Pumps Describe the basic operation of a fixed displacement radial piston pump. Describe the basic operation of a variable displacement radial piston pump. Describe the basic operation of a fixed displacement axial pist on pump. Describe the basic operation of a variable displacement axial pump. Describe the basic operation of a fixed displacement bent-axis pump. Describe the basic operation of a variable displacement bent-axis pump. Describe the basic operation of a pressure compensated axial pist on pump.
Subjects: Types of Pumps Pump Basics Positive Displacement Pumps Rotary Pumps Gear Pumps Vane Pumps Piston Pumps Radial Piston Pumps Axial Pist on Pumps Pressure Compensated Piston Pumps Course 135 of 245
Maintenance
HYDRAULICS: Routine Maintenance (IHRDC_OM_AHHRM)
Overview: This unit is designed to familiarize trainees with tasks associated with t he regular or routine maintenance of hydraulic systems. Aft er completing t his unit, trainees should be able t o describe general considerations and safety precautions associated with routine maintenance. They should also be able t o describe procedures for performing external inspect ions and for maintaining t he hydraulic fluid, the reservoir, filters and strainers, accumulators, and heat exchangers. Duration: 2 hrs Objectives: General Recommendations Describe what routine maintenance is, and state its purpose. Describe four steps involved in establishing a rout ine maintenance program. Describe personal protective equipment and clot hing that should be worn by personnel performing routine maintenance tasks. Ident ify hazards of hydraulic fluid spills and describe one method of cleaning up a spill. Describe what is generally meant by lock out and tag out and describe the purpose of such a procedure. System Inspections List components that are typically checked during a visual inspection and explain why t hey are checked. Describe problems to look for during a visual inspection of fluid lines on an operating hydraulic system. Ident ify areas where fluid leaks are commonly found, and describe possible causes. Describe the t erm starving t he pump and identify one possible cause. Explain what a sounding rod is, and describe specific conditions or malfunctions that can cause component s to make unusual sounds. Define t he term hot spot and explain how hot spots can be detected in a hydraulic system. List possible causes of excessive vibration in a hydraulic system and list some possible results of this problem. Component Maintenance Describe two types of contaminants that are t ypically found in hydraulic fluid, and identify likely causes of each. Describe how filt ers and strainers are maint ained and explain why they must be maintained. Describe a procedure for cleaning a hydraulic reservoir and explain t he purpose of this task. Explain the purpose of checking t he charge of a nitrogen-charged accumulator. Describe a procedure for cleaning an air-cooled heat exchanger, and explain why t his is necessary.
Subjects: General Recommendations Establishing a Program Safety System Inspections Visual Inspections Other External Inspections Component Maintenance Fluid and Reservoir Accumulators and Heat Exchangers Course 136 of 245
Maintenance
HYDRAULICS: Troubleshooting (IHRDC_OM_AHHTR)
Overview: This unit is designed to familiarize trainees with general steps for analyzing problems in hydraulic syst ems. After completing this unit, trainees should be able t o explain how to ident ify problems in hydraulic systems and describe common problems associated with hydraulic syst em components. Duration: 2 hrs Objectives: Problem Analysis Ident ify prerequisite knowledge and skills t hat mechanics should have in order to troubleshoot hydraulic systems effectively. Ident ify the basic steps of the troubleshooting process. Describe the process of identifying a problem and taking prevent ive action in immediat e response to a hydraulic system operating problem. Describe how to evaluate common general sympt oms of problems in a hydraulic system. Describe common methods for applying the process of elimination to troubleshoot problems in hydraulic systems. Describe major concerns associated wit h correcting problems and safely returning a hydraulic system to service. Component Problems Describe common problems that may be associated with the hydraulic fluid, hoses, and accumulators in a hydraulic system. Describe common problems that may be associated with the valves in a hydraulic system. Describe common problems that may be associated with the cylinders in a hydraulic system. Describe common problems that may be associated with the pumps and hydraulic motors in a hydraulic system.
Subjects: Problem Analysis Basics Immediate Response Problem Correct ion Component Problems Fluid, Hose, and Accumulator Problems Valve Problems Cylinder Problems Pump and Hydraulic Mot or Problems Course 137 of 245
Maintenance
HYDRAULICS: Valves 1 (IHRDC_OM_AHHV1)
Overview: This unit is designed to familiarize trainees with the basic design and operation of various types of valves used in hydraulic systems. Aft er completing t his unit, trainees will be able to describe the functions of flow and pressure in a hydraulic system, and identify and describe various types of manually adjusted valves, sliding spool valves, and spring-biased valves. They should also be able to describe various ways in which valves can be actuated. Duration: 2 hrs Objectives: Valve Basics Define flow and describe its function in a hydraulic system. Define pressure and describe its funct ion in a hydraulic system. Explain the functions of valves in a hydraulic system. Explain the t erm throttling. Ident ify and describe a typical needle valve. Ident ify and describe a typical globe valve. Ident ify and describe a typical plug valve. Ident ify and describe a typical ball valve. Ident ify and describe a typical gate valve. Actuated Valves Ident ify and describe the main components of a typical directional control, sliding spool valve. Explain positioning of a directional control sliding spool valve. Ident ify and describe a typical check valve. Ident ify and describe a typical relief valve. Ident ify and describe a typical pressure reducing valve. Define cracking pressure and pressure override. Describe three methods of valve actuat ion. Explain what a solenoid does, and describe two different types of solenoids. Describe a servo system and explain what it does. Describe what a pilot-operated valve is and how it works.
Subjects: Valve Basics Basic Principles Manually-Adjusted Valves Actuated Valves Sliding Spool Valves Spring-Biased Valves Methods of Actuation Course 138 of 245
Maintenance
HYDRAULICS: Valves 2 (IHRDC_OM_AHHV2)
Overview: This unit is designed to familiarize trainees with the functions performed by various types of valves in hydraulic syst ems. After completing this unit, t rainees should be able to describe how valves control flow rate, flow direction, and pressure in a hydraulic system. They should be able to describe the basic operat ion of a pressure-compensated flow control valve, a temperaturecompensated flow control valve, various types of flow control circuit s, a pressure reducing valve, a relief valve, a sequence valve, and a counterbalance valve. Duration: 2 hrs Objectives: Flow and Directional Control Describe what a non-adjustable orifice is and what it does. List three factors that affect t hrottled flow through a valve. Describe how a pressure-compensated flow control valve works. Describe how a temperature-compensated flow control valve works. Ident ify three different flow control circuits. Describe a bleed-off circuit and how it is used. Describe a meter-in circuit and how it is used. Describe a meter-out circuit and how it is used. Explain how a directional control sliding spool valve controls fluid direction in a hydraulic syst em. Pressure Control Explain what a pressure reducing valve does and how it works. Explain what a relief valve does and how it works. Explain what a sequence valve does and how it works. Explain what a counterbalance valve does and how it works.
Subjects: Flow and Directional Control Flow Cont rol Valves Flow Cont rol Circuits Directional Control Pressure Control Pressure Reduction and Relief Sequencing and Counterbalancing Course 139 of 245
Maintenance
LUBRICATION: Lubrication Basics (IHRDC_OM_AMLBA)
Overview: This interactive training unit is designed to familiarize trainees wit h the properties and uses of various types of lubricants. After completing this unit, t rainees should be able to explain why lubricants are used and describe some charact eristic properties of lubricants. They should also be able t o describe procedures for storing, handling, and applying lubricants. Duration: 2 hrs Objectives: Introduction to Lubrication Describe three types of friction, three types of lubricants, and t hree levels of lubrication. Describe some of the characteristic propert ies of lubricants. Ident ify factors that usually affect the selection of a lubricant for a specific situation. Explain how to use a typical lubrication chart. Storing and Handling Lubricants Describe proper procedures for, and safety concerns associated with the storage of lubricants. Describe common types of lubricant equipment. Describe common safety concerns and precautions that are associated with t he handling of lubricant s. Describe common procedures for handling, dispensing, and applying lubricants. Oils and Greases Describe some of the typical groups of general oils. Describe common methods of oil lubrication. Describe some unique properties of greases. Compare the uses of greases and oils for lubrication. Describe some common methods of applying grease.
Subjects: Introduction to Lubrication Friction and Lubrication Properties of Lubricants Lubricant Selection Storing and Handling Lubricants Lubricant Storage Lubrication Equipment Lubricant Handling Oils and Greases Types of Oils Oil Lubrication Properties of Grease Applying Grease Course 140 of 245
Maintenance
MATH: Basics of Math (IHRDC_OM_AMMBA)
Overview: This interactive training unit is designed to familiarize trainees wit h basic mathematical applications that can be used on the job. After completing this unit, trainees should be able to int erpret measurements that include fractions and decimal values, measurement s in English and metric units, and perform mathematical applications involving fractions and decimals. They should also be able to calculate dimensions associated with rect angles, t riangles, and circles. Duration: 2 hrs Objectives: Working With Numbers Interpret measurements that include fract ions. Add and subt ract fractional measurements. Multiply and divide fractional measurements. Convert a fraction to a decimal, and a decimal to a fraction. Convert a decimal to a percent, and a percent to a decimal. Perform mathematical operations with decimal numbers. Use a calculator to perform mathematical operations. Round off a decimal to a specific number of places. Interpret measurements in metric units. Angles and Shapes Explain what an angle is, and how angles are measured. Explain what a rectangle is, and define the terms length and widt h. Explain what a t riangle is, and define the terms base and height. Explain what a circle is, and define the terms diameter and radius. Calculate the perimeter of a rect angle. Calculate the length of the hypotenuse of a right angle. Calculate the circumference of a circle. Areas and Volumes Calculate the area of a rectangle, a right triangle, and a circle. Calculate the volume of a rect angular solid. Calculate the volume of a cylinder.
Subjects: Working With Numbers Fractions and Measurements Working Wit h Fractions Decimals Using a Calculator Metric Measurement s Angles and Shapes Angles Rect angles, Triangles, and Circles Working Wit h Shapes Areas and Volumes Areas Volumes Course 141 of 245
Maintenance
PIPES AND VALVES: Motor Operators (IHRDC_OM_AMPMO)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion and maintenance of motor operators. Aft er completing t his unit, trainees should be able t o identify the main parts of a motor operator and explain how a motor operator opens and closes a valve. They should also be able t o describe the parts and operation of limit and torque switches, and explain how these swit ches can be replaced and adjusted. In addition, they should be able to describe preventive maintenance procedures for a motor operator and explain how to troubleshoot a motor operator problem. Duration: 2 hrs Objectives: Mechanical Components Name the basic parts of a typical mot or operator and describe the function of each part . Describe how the gears in a typical motor operator work during motor-driven operation and during manual operation. Electrical Controls Describe the parts and operation of a typical rotary drum limit switch, and explain how the switch is replaced and adjusted. Describe the parts and operation of a typical t orque switch, and explain how the switch is replaced and adjusted. Maintenance and Troubleshooting Describe preventive maintenance procedures for a typical motor operat or. Explain how to troubleshoot a typical mot or operator.
Subjects: Mechanical Components Basic Component s Motor and Gear Operation Electrical Controls Limit Switches Torque Switches Maintenance and Troubleshooting Prevent ive Maintenance Troubleshooting Course 142 of 245
Maintenance
PIPES AND VALVES: Pipes and Pipe Fittings (IHRDC_OM_AMPPP)
Overview: This interactive training unit is designed to familiarize trainees wit h common types of pipes, pipe joints, and pipe fit tings, and to provide general guidelines for working with pipes. After completing this unit , trainees should be able to identify common materials used to make pipes, and explain how pipes are identified and sized. They should also be able to identify common t ypes of pipe joints and pipe fittings, and describe procedures for calculating pipe lengths, cutting pipe, and threading pipe. Duration: 2 hrs Objectives: Basics Ident ify some common materials used to make pipe and describe characterist ics of those materials. Describe how pipes are usually sized and explain how t hey are marked for identification. Describe some common signs of wear and damage t o look for during a pipe inspection. State some basic guidelines for handling and storing pipes. Joints and Fittings Ident ify some common types of pipe joint s and describe their characteristics. Ident ify some common types of pipe fit tings and describe their funct ions. Installation Describe some basic met hods for calculating the length of pipe needed bet ween fittings. Ident ify some common tools used to cut pipe and explain how they operate. Explain how to use a pipe die to cut t hreads in a pipe.
Subjects: Basics Pipe Materials Sizes and Identification Inspection, Handling, and Storage Joints and Fittings Joints Fitt ings Installation Calculating Pipe Length Cutt ing Pipe Threading Pipe Course 143 of 245
Maintenance
PIPES AND VALVES: Safety Valves (IHRDC_OM_AMPSV)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion and maintenance of types of safety valves commonly found in indust rial facilities. Aft er completing t his unit, trainees should be able t o describe the parts and operation of a huddling chamber safety valve, a safet y-relief valve, and a pilot-actuated relief valve. They should also be able t o describe procedures for inspecting, disassembling, reassembling, and testing a safet y valve. Duration: 2 hrs Objectives: Types of Safety Valves Describe the parts and operation of a typical huddling chamber safety valve. Describe the parts and operation of a typical safety-relief valve and a typical pilot-actuat ed valve. Safety Valve Maintenance Describe the procedure for performing an external inspect ion on a safety valve. Describe procedures for disassembling a safety valve and inspecting its internal components. Describe procedures for reassembling and testing a safety valve before put ting it in service.
Subjects: Types of Safety Valves Huddling Chamber Safety Valves Specialized Relief Valves Safety Valve Maintenance External Inspection Disassembly and Inspection Reassembly and Testing Course 144 of 245
Maintenance
PIPES AND VALVES: Steam Traps (IHRDC_OM_AMPST)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion and maintenance of types of steam t raps commonly found in industrial facilities. After completing this unit, trainees should be able to describe functions commonly performed by steam t raps, describe common t ypes of steam traps, and describe procedures for performing steam trap surveys and replacing worn or damaged steam trap components. Duration: 2 hrs Objectives: Basics Describe functions typically performed by steam traps. Describe the components of a typical steam trap station. Types of Steam Traps Describe the basic operation of two common types of mechanical steam traps: inverted bucket and float, and t hermostatic. Describe the basic operation of two common types of thermostatic steam traps: bellows and bi-metallic.Describe t he basic operation of a typical thermodynamic disc-type steam trap. Inspecting and Replacing Describe what to check for during a survey or inspection of a steam trap st at ion. Describe typical procedures for performing a t emperature inspection, a sound inspection, and a visual inspection of a steam trap. Describe a typical procedure for replacing worn or damaged steam trap component s.
Subjects: Basics Functions of Steam Traps Steam Trap St at ions Types of Steam Traps Mechanical Traps Thermostatic Traps Inspecting and Replacing Surveying Steam Trap Stations Surveying Steam Traps Replacing Steam Traps Course 145 of 245
Maintenance
PIPES AND VALVES: Valve Maintenance (IHRDC_OM_AMPV2)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic procedures for performing routing maintenance on a valve and for performing a valve overhaul. After completing this unit, t rainees should be able to describe tasks involved in preparing for valve maint enance and explain how to adjust and replace valve packing. They should also be able to describe how to disassemble a valve, inspect its part s, perform maintenance on it, and reassemble it. Duration: 2 hrs Objectives: Routine Maintenance Describe tasks typically complet ed in preparation for performing maintenance on a valve. Describe how to adjust packing in a valve. Describe how to remove packing from a valve. Describe how to replace the packing in a valve. Valve Overhaul Describe a basic procedure for disassembling a valve. Describe tasks associated with inspecting the parts of a valve. Explain how lapping and spotting-in are performed on a valve seating area. Describe a basic procedure for reassembling a valve and returning it t o service.
Subjects: Routine Maintenance Maintenance Preparations Adjusting and Replacing Packing Valve Overhaul Disassembly and Inspection Maintenance Reassembly Course 146 of 245
Maintenance
PIPES AND VALVES: Valve Types and Operation (IHRDC_OM_AMPV1)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic components and operation of valves commonly found in industrial sites. Aft er completing t his unit, trainees should be able t o explain how valves can be classified, describe the parts and operation of various types of valves, and describe how valves can be operated. Duration: 2 hrs Objectives: Valve Fundamentals Describe the basic purpose of a valve. Ident ify the basic components of a valve. Ident ify the valves that are commonly classified. Valve Types Describe the basic components and operation of a gate valve. Describe the basic components and operation of common types of globe valves. Describe the basic components and operation of a plug valve, a ball valve, and a butterfly valve. Describe the basic components and operation of a diaphragm valve. Describe the basic components and operation of a swing check valve, a lift check valve, and a ball check valve. Valve Operation Describe how a handwheel is used to operate a valve. Describe how a handle is used to operate a valve. Ident ify and describe common types of pneumatically, hydraulically, and electrically powered mechanical operators for valves.
Subjects: Valve Fundamentals Valve Characteristics Valve Classificat ions Valve Types Gate Valves Globe Valves Plug, Ball, and Butterfly Valves Diaphragm Valves Check Valves Valve Operation Manual Operation Mechanical Operators Course 147 of 245
Maintenance
PUMPS: Centrifugal Pump Basics and Troubleshooting (IHRDC_OM_AMPC1)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion of centrifugal pumps and general procedures for troubleshooting centrifugal pump problems. Aft er completing t his unit, trainees should be able t o describe the basic operation of a centrifugal pump, explain how cent rifugal pumps can be classified, identify the main part s of a centrifugal pump, and describe problems that can occur in them. Duration: 2 hrs Objectives: Pump Basics Name the two most common t ypes of pumps and describe t he differences between them. Describe the basic operation of a centrifugal pump. Ident ify and describe characteristics that are used to classify cent rifugal pumps. Describe advantages and applications of various types of centrifugal pumps. Pump Parts Name the main ext ernal parts of a centrifugal pump and describe the function of each. Name the main internal part s of a centrifugal pump and describe the function of each. Troubleshooting Describe some general considerations associated wit h troubleshooting a centrifugal pump. Describe symptoms of a centrifugal pump problem t hat can be heard, and list the probable causes of t hose symptoms. Describe the causes and effects of cavitation, and explain how it can be eliminat ed. Describe symptoms of a centrifugal pump problem t hat can be seen, and list the probable causes of those symptoms. Describe symptoms of a centrifugal pump problem t hat can be felt, and list the probable causes of those symptoms. Describe some general preparations for working on a pump. Describe some problems that can be detected by inspecting the int ernal parts of a centrifugal pump.
Subjects: Pump Basics Types of Pumps Centrifugal Pump Operat ion Classification of Centrifugal Pumps Pump Parts External Parts Internal Part s Troubleshooting General Considerations Common Symptoms Internal Problems Course 148 of 245
Maintenance
PUMPS: Centrifugal Pump Overhaul (IHRDC_OM_AMPC2)
Overview: This interactive training unit is designed to familiarize trainees wit h basic procedures for overhauling a cent rifugal pump. Aft er completing this unit, t rainees should be able to describe preparations for a centrifugal pump overhaul, procedures for disassembling a centrifugal pump, inspecting its parts, and reassembling it. Duration: 2 hrs Objectives: Preliminary Steps Describe general preparations for a centrifugal pump overhaul. Describe safety precautions that should be taken as part of preparing t o work on a centrifugal pump. Describe a procedure for removing the upper half of a horizontally split centrifugal pump casing. Describe a procedure for preliminary inspection of the internal parts of a centrifugal pump. Disassembly and Assembly Describe a procedure for disassembling t he internal parts of a centrifugal pump. Ident ify the parts of a centrifugal pump t o be inspect ed and state what to look for in each part. Describe how to measure the clearance between a casing wearing ring and an impeller. Explain how to determine if casing wearing rings are round. Describe the procedure for performing a shaft runout test . Reassembly List steps that are commonly taken in preparing to reassemble a centrifugal pump. Describe a procedure for reinstalling an impeller. Describe a procedure for reassembling and reinstalling a rotor. Describe a procedure for reassembling the casing of a centrifugal pump.
Subjects: Preliminary Steps Preparation Casing Removal Preliminary Inspect ion Disassembly and Inspection Disassembly Inspection Wearing Ring Measurements Shaft Tests Reassembly Reinstalling the Impeller Reassembling and Reinstalling the Rot or Reassembling the Casing Course 149 of 245
Maintenance
PUMPS: Multistage Centrifugal (IHRDC_OM_AMPMC)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion, disassembly, and reassembly of a typical multistage centrifugal pump. After completing this unit, trainees should be able to describe the components and operation of a multistage cent rifugal pump and explain how this kind of pump can be disassembled and reassembled when necessary. Duration: 2 hrs Objectives: Basic Concepts Ident ifyand describe the component s of a typical multistage centrifugal pump. Describe the operation of a typical multist age centrifugal pump. Describe techniques t hat are commonly used to minimize axial thrust in a multistage centrifugal pump. Describe techniques t hat are commonly used to minimize radial thrust in a multistage centrifugal pump. Ident ify problems commonly found in mult istage centrifugal pumps. Describe techniques used to ident ify problems in a mult istage centrifugal pump. Pump Assembly Describe tasks that are commonly part of preparing for a pump disassembly. Describe a general procedure for disassembling an axially split multistage centrifugal pump. Describe tasks that are commonly performed when a radially split multistage centrifugal pump is disassembled. Describe tasks that are commonly performed as part of removing components from a pump shaft assembly. Pump Reassembly Describe tasks that are commonly performed when pump shaft assembly components are installed. Describe a general procedure for reassembling an axially split multistage centrifugal pump. Describe tasks that are commonly performed when a radially split multistage centrifugal pump is reassembled. Describe tasks that are commonly performed when a mult istage centrifugal pump is returned to service.
Subjects: Basic Concepts Types of Multistage Cent rifugal Pumps Components and Operation Minimizing Axial and Radial Thrust Ident ifying Common Problems Pump Disassembly Preparations Axially Split Pumps Radially Split Pumps Shaft Assemblies Pump Reassembly Shaft Assemblies Axially Split Pumps Radially Split Pumps Return to Service Course 150 of 245
Maintenance
PUMPS: Positive Displacement (IHRDC_OM_AMPPD)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic operat ion and maintenance of positive displacement pumps. After completing this unit, t rainees should be able to describe the basic operation of various t ypes of reciprocating and rotary positive displacement pumps. They should also be able t o describe how to prepare for overhauling a posit ive displacement pump, disassemble the pump, clean and inspect its parts, and then reassemble it. Duration: 2 hrs Objectives: Types and Operation Describe the basic operation of a pist on pump. Describe the basic operation of a plunger pump. Describe the basic operation of a diaphragm pump. Describe the basic operation of a double-acting pump. Explain what a duplex pump is. Describe the basic operation of a screw pump. Describe the basic operation of a gear pump. Describe the basic operation of a lobe pump. Describe the basic operation of a sliding vane pump. Describe the basic operation of a flexible member pump. Overhaul Preparations and Pump Assembly Describe general preparations for a pump overhaul. Describe basic tasks associated wit h disconnecting a pump from its motor and bedplate. Explain how to remove the timing gears and the outboard bearing bracket from a two-screw rot ary pump. Describe a basic procedure for removing mechanical seals from a t wo-screw rotary pump. Describe basic guidelines for removing the rotors from a two-screw rotary pump. Cleaning, Inspection, and Reassembly Describe precautions associated with cleaning pump component s. Describe basic steps for inspect ing the components of a two-screw rotary pump. Describe general preparations that should be made before a pump is reassembled. Describe a basic procedure for reassembling a two-screw rotary pump.
Subjects: Types and Operation Reciprocating Pumps Rotary Pumps Overhaul Preparations and Pump Assembly Overhaul Preparations Init ial Disassembly Final Disassembly Cleaning, Inspection and Reassembly Cleaning and Inspection Reassembly Course 151 of 245
Maintenance
RIGGING: Basic Lifting (IHRDC_OM_AMRLL)
Overview: This interactive training unit is designed to familiarize trainees wit h the proper use of devices designed to lift and move loads. Aft er completing t his unit, trainees should be able t o describe how to use a simple block and tackle, a compound block and t ackle, a hoist, a jack, a winch, a turnbuckle, and a load leveler. They should also be able to describe t he effects of sling angles and hitch pat terns on a sling's lifting ability. Duration: 2 hrs Objectives: Block and Tackle Ident ify the parts of a simple block and t ackle. Describe the proper use of a simple block and tackle. Ident ify the parts of a typical compound block and t ackle. Describe inspections that are typically performed before a compound block and tackle is used. Explain what is involved in reeving a block and t ackle. Describe the proper use of a compound block and tackle. Define mechanical advant age. Explain how to use a formula to select the appropriate block and tackle needed to lift a given weight. Hoists, Jacks, and Winches Describe the basic operation of a chain hoist. Describe the basic operation of a come-along. Describe the basic operation of a ratchet jack. Describe the basic operation of a screw jack. Describe the basic operation of a hydraulic jack. Describe basic safety precautions associated with using a jack. Describe the basic operation of a winch. Slings and Levelers Describe the effects of sling angles on a sling's lift ing capacity. Describe the effects of hitch patterns on a sling's lifting capacit y. Describe how a turnbuckle can be used to adjust sling length. Describe how a load leveler can be used to balance a load.
Subjects: Block and Tackle Simple Block and Tackle Compound Block and Tackle Mechanical Advantage Hoists, Jacks and Winches Hoist s Jacks Winches Slings and Levelers Slings Leveling Devices Course 152 of 245
Maintenance
RIGGING: Heavy Lifting (IHRDC_OM_AMRHL)
Overview: This interactive training unit is designed to familiarize trainees wit h equipment and procedures used for lifting and moving heavy objects. After completing this unit, t rainees should be able to describe various types of rigging hardware and cranes. They should also be able t o explain how to use lifting capacity charts and how to balance loads. Duration: 2 hrs Objectives: Heavy Lifting Equipment Describe the following rigging components and identify basic inspect ion checks that should be made to t hem: Shackles Hooks Swivels Turnbuckles Rigging links and equalizer plates Lifting lugs and eyebolts Spreader beams and lifting beams Tag lines Heavy Lifting Procedures Describe how to read and interpret lifting capacity charts. Describe load balancing techniques commonly used during heavy lifting. Describe basic procedures involved in planning and completing a heavy lifting job using a crawler crane.
Subjects: Heavy Lifting Equipment Hardware Bridge Cranes Boom Cranes Crane Inspections Heavy Lifting Procedures Capacity Charts Load Balancing Crawler Crane Job Course 153 of 245
Maintenance
RIGGING: Ladders and Scaffolds (IHRDC_OM_AMRLS)
Overview: This interactive training unit is designed to familiarize trainees wit h various types of ladders and scaffolds that enable personnel t o work at elevated height s. After completing this unit, trainees should be able to describe how t o select the proper ladder for a job and then use t he ladder safely. They should also be able to describe general safet y precautions associated wit h using scaffolds, and the basic operat ion and use of various types of fixed and powered scaffolds. Duration: 2 hrs Objectives: Ladders Describe various types of ladders and their ratings. Explain how to select t he proper ladder for the job. Explain how to use a ladder safely. Fixed Scaffolds Describe general safety precautions associated with stationary, or fixed scaffolds. Describe the assembly, use, and disassembly of a systems scaffold. Describe the assembly, use, and disassembly of a t ubular welded frame scaffold. Powered Scaffolds Describe the basic components and operation of a pneumat ic scaffold. Describe the basic components and operation of a hydraulic scaffold.
Subjects: Ladders Types of Ladders Ladder Safety Fixed Scaffolds Scaffold Safety Systems Scaffolds Tubular Welded Frame Scaffolds Powered Scaffolds Pneumatic Scaffolds Hydraulic Scaffolds Course 154 of 245
Maintenance
RIGGING: Overview (IHRDC_OM_AMROV)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic principles involved in moving materials and equipment from one place to another. After complet ing this unit, trainees should be able to describe t he funct ions of various t ypes of rigging equipment and explain how t o select and inspect equipment for a job that involves rigging. Duration: 2 hrs Objectives: Introduction to Rigging Describe the basic charact eristics of fiber rope, wire rope, and chain. Ident ify and describe the functions of t he following end fittings and connectors: eye splices, thimbles, wire rope clips, shackles, sockets, wedge socket s and hooks. Ident ify and describe the uses bridle slings, choker hitch slings and basket hitch slings. Explain how to inspect wire rope, chains, synthetic web slings, hooks, shackles and socket s, and equipment to be rigged. Derricks and Cranes Ident ify the following types of derricks: A-frame and Gin pole derricks Guy derricks and Stiffleg derricks Chicago boom derricks Ident ify the following types of cranes: Crawler cranes Truck-mounted cranes Truck-mounted hydraulic cranes Gantry-mounted cranes Tower-mounted cranes Hammerhead cranes Rough-terrain cranes Carrydeck cranes Describe hand signals commonly used for different types of cranes. Rigging and Moving Loads Explain how to estimate the size and weight of a load. Explain how to find a load's center of gravity. Ident ify the following types of knots: bowline, running bowline, timber hitch, half hitch, square know, clove hitch and barrel hitch. Describe the basic rigging safety precautions. Describe basic steps involved in planning a rigging job. Describe how to select t he proper equipment for a rigging job.
Subjects: Introduction to Rigging Ropes and Chains End Fittings, Connectors, and Slings Equipment Inspections Derricks and Cranes Derricks and Cranes Crane Hand Signals Rigging and Moving Loads Estimating Size, Weight, and Center of Gravity Tying Knots Rigging and Moving Materials and Equipment Course 155 of 245
Maintenance
SAFETY: Basics (IHRDC_OM_AMSBA)
Overview: This interactive training unit is designed to familiarize trainees wit h hazards they may encounter on the job, and ways in which t hey can protect t hemselves from these hazards. Aft er completing t his unit, trainees should be able t o describe causes of on-the-job accident s, explain how company safety policies can help prevent accidents, describe actions t hat can be taken to make a work site safe, and explain how workers can protect themselves from electrical hazards and fire hazards. Duration: 2 hrs Objectives: Preventing Accidents Describe causes of on-the-job accidents. Explain how good housekeeping can prevent accidents. Explain why it is important to follow all company safety policies. Explain why it is important to report on-the-job injuries, accident s, and near misses. Explain why it is important for workers to know and follow company evacuation procedures. Work Site Safety Describe typical personal protective equipment, and explain when and why each type of equipment is used. Describe how to inspect and care for personal protect ive equipment . Describe safe procedures for lift ing heavy object s. Describe common workplace hazards. Describe rules and guidelines for general work site safety. Describe safety requirements for working in confined spaces. Describe safe pract ices for operating or working near motorized vehicles. Describe safe lockout/tagout procedures. Describe safe pract ices for working around barriers and barricades. State the purpose of the OSHA Hazard Communicat ion St andard and the function of Material Safety Data Sheets. Describe rules and guidelines for working safely around hazardous substances. Describe how to inspect and work safely with ladders. Describe how to inspect and work safely with scaffolds. Electrical and Fire Safety Describe typical work site electrical hazards. Describe safe pract ices for working around electrical hazards. Describe actions t hat should be taken when an electrical shock occurs. Explain how fires start. Describe common fire prevent ion practices. Ident ify the classes of fires and the type of extinguisher to use for each class. Describe actions t hat should be taken if a fire occurs.
Subjects: Preventing Accidents Accidents; Safety Policies Work Site Safety Personal Protection; Safe Work Practices Equipment and Materials Ladders and Scaffolds Electrical and Fire Safety Course 156 of 245
Maintenance
SAFETY: Chemical Health Hazards (IHRDC_OM_AMSHS)
Overview: This interactive training unit is designed to familiarize trainees wit h chemical health hazards that might be present in the workplace. Aft er completing t his unit, trainees should be able t o identify various types of physical hazards and health hazards associated with chemicals and describe how they can protect themselves from those hazards. Duration: 2 hrs Objectives: Identification Define t he terms physical hazard and health hazard and identify examples of each. Define t he term route of entry and describe three examples. Define t he terms acute effects and chronic effects and describe examples of each. Describe information that is provided on Material Safety Data Sheets. Explain what the colors and numbers represent in the NFPA fire diamond. Explain what the colors and numbers represent in the HMIS labeling syst em. Explain what the colors and numbers represent in the DOT labeling system. Protection Describe two types of respirat ors. Describe how to determine if a respirator is in safe working condition. Describe how to properly select and use goggles. Describe how to properly select and use chemical-resist ant clothing. Describe two properties of a chemical that can indicat e a hazardous situation. Describe general steps for responding t o a chemical emergency.
Subjects: Identification Types of Hazards Documents and Labels Protection Respirators Clothing and Equipment Emergency Response Course 157 of 245
Maintenance
SAFETY: Electrical (IHRDC_OM_AMSEL)
Overview: The purpose of this unit is to give trainees a general understanding of basic principles of electricit y and electrical safety. At t he conclusion of htis unit, trainees will have a basic understanding of various aspects of working safely around elect rical equipment Duration: 2 hrs Objectives: Electrical Concepts Describe the basic elect rical quantities of current, voltage, and resistance. Shock State what an electrical shock is. Describe factors that affect the severity of an electrical shock. Describe the physical effects of current passing through the human body. Hazards Describe hazards associated with working near electrical equipment. Protection Describe ways of providing protect ion to personnel from hazards associated with electricit y. Emergencies Describe how to safely give aid to an electrical shock victim. Describe how to safely respond to an electrical fire.
Subjects: Electrical Concepts Friend or Foe? Current Volt age Resistance Shock What Is Shock? Amount of Current Length of Time Path Through the Body Effects Hazards High Voltage Area Overloaded Circuits Damaged Cords Bare Connect ors Long and Tall Objects Mobile Equipment Standing Water Course 158 of 245
Maintenance
SEALS: Gaskets and Packing (IHRDC_OM_AMMSG)
Overview: This interactive training unit is designed to familiarize trainees wit h the use of gaskets and packing to prevent or minimize leakage from equipment such as pumps and valves. After completing this unit, trainees should be able to identify various types of gaskets and explain how t o cut and install gaskets. They should also be able to identify the components of a packing gland and explain how to remove and install packing. Duration: 2 hrs Objectives: Gaskets Explain how gaskets work. Describe common types of gaskets. Describe a procedure for using a gasket cutter. Describe a procedure for cut ting a gasket by hand. Describe a procedure for installing a basic flat gasket on a pump casing. Describe a procedure for installing an "O" ring on a flange. Packing Describe packing and explain how it works. Describe components of a typical packing gland. Describe compression and hydraulic packing. Describe a procedure for removing old packing from a pump. Describe a procedure for installing new packing on a pump.
Subjects: Gaskets Operation Cutt ing Gasket s Installing Gaskets Packing Operation Packing Removal Packing Installation Course 159 of 245
Maintenance
SEALS: Mechanical (IHRDC_OM_AMMES)
Overview: This interactive training unit is designed to familiarize trainees wit h the use and installation of various types of mechanical seals. Aft er completing t his unit, trainees should be able t o identify the components of commonly used types of mechanical seals, explain why mechanical seals can fail, and identify causes of seal failures by examining seal components. They should also be able to disassemble a pump t o remove a mechanical seal, take the appropriat e installation measurements, and install a new mechanical seal. Duration: 2 hrs Objectives: Introduction Ident ify the component s of a typical mechanical seal. Describe how a typical mechanical seal operates. Ident ify commonly used types of mechanical seals. Describe some common causes of mechanical seal failures. Explain how to identify causes of seal failures by examining seal components. Preparations for Seal Installations Describe one way to disassemble a pump to remove a mechanical seal. Describe checks and measurements commonly made during and after t he pump disassembly to prepare for a mechanical seal inst allation. Seal Installations Explain how certain pump component s are temporarily reassembled so that preliminary measurements can be t aken before a new mechanical seal is installed. Describe one way to install an inside pusher seal. Describe one way to install an elastomer bellows seal. Describe one way to install a metal bellows seal. Describe one way to install an outside seal. Describe one way to install a cartridge seal.
Subjects: Introduction Seal Components Types of Mechanical Seals Mechanical Seal Failures Preparations for Seal Installations Pump Disassembly Pump Component Checks Seal Installations Installation Measurement s Inside Pusher Seal Installation Non-Pusher Seal Installation Out side and Cartridge Seals Course 160 of 245
Maintenance
SHAFT ALIGNMENT: Fundamentals (IHRDC_OM_AMSAF)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic principles associated with measuring and correcting shaft misalignment. Aft er completing t his unit, trainees should be able t o describe the basic types of misalignment, conditions t hat may affect shaft alignment, and how to perform a rough alignment . Duration: 2 hrs Objectives: Introduction Describe the basic types of misalignment. Describe how a proper orientation t o equipment should be established prior to alignment procedure. Describe basic measurements that are necessary for determining misalignment. Describe how misalignment is corrected. Describe the basic operation of two t ypes of dial indicators commonly used for alignment work. Conditions Affecting Alignment Ident ify common foundation problems and describe preparations performed on equipment foundations. Describe what a soft foot is. Describe a procedure for measuring and correcting a soft foot condition. Describe what pipe st rain is, and how it can affect shaft alignment . Describe a procedure for measuring pipe strain. Describe how a bent shaft or bad bearings can affect shaft alignment. Describe a procedure for measuring shaft runout. Describe what thermal growt h is and how it can affect shaft alignment. Describe procedures for measuring thermal growth. Rough Alignment Procedure Describe a procedure for measuring and setting the mechanical center of a pump's shaft. Describe a procedure for determining the magnetic center of an elect ric mot or. Describe a rough alignment procedure using the straightedge and feeler gage met hod.
Subjects: Introduction Types of Misalignment Alignment Orientation Basic Measurements and Corrections Conditions Affecting Alignment Foundat ion Problems Soft Foot Pipe Strain Shaft and Bearing Problems Thermal Growth Rough Alignment Procedure Basic Preparations Straightedge and Feeler Gage Method Course 161 of 245
Maintenance
SHAFT ALIGNMENT: Reverse Dial and Laser (IHRDC_OM_AMSRD)
Overview: This interactive training unit is designed to familiarize trainees wit h equipment and procedures for aligning shafts using the reverse dial method and using a laser system. After complet ing this unit, trainees should be able to prepare and set up equipment for a reverse dial and laser-based alignment. They should also be able to measure shaft misalignment and determine how it should be corrected so t hat the alignment is within specified tolerances. Duration: 2 hrs Objectives: Preparing for a Reverse Dial Alignment Review the basic types of shaft misalignment . Describe the arrangement of instrument s used to perform a reverse alignment. Describe the general types of preparations required for a shaft alignment using the reverse dial met hod. Performing a Reverse Dial Alignment Explain how to measure misalignment in the vertical plane using the reverse dial method. Explain how to construct a graph representing misalignment in the vertical plane that is measured by the reverse dial method. Describe how to correct misalignment in the vert ical plane. Explain how to measure misalignment in the horizontal plane using the reverse dial met hod. Explain how to construct a graph representing misalignment in the horizontal plane that is measured by the reverse dial method. Describe how to correct misalignment in the horizont al plane. Explain how to determine if a shaft alignment is within tolerances. Laser Alignment Describe the basic part s and operation of a laser alignment system.
Subjects: Preparing for a Reverse Dial Alignment Fundamentals Equipment Preparations Performing a Reverse Dial Alignment Overview Measuring Vertical Plane Alignment Measuring Horizontal Plane Alignment Graphing and Correct ing Horizontal Misalignment Alighment Tolerances Laser Alignment System Parts and Operation Course 162 of 245
Maintenance
SHAFT ALIGNMENT: Rim and Face (IHRDC_OM_AMSRF)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic principles associated with measuring and correcting shaft misalignment using the rim and face method. After complet ing this unit, trainees should be able to describe t he basic types of misalignment, general preparations for a rim and face shaft alignment procedure, and explain how to use t he rim and face shaft alignment procedure. They should also be able to explain how to use the rim and face method to measure and correct misalignment on horizontally mounted equipment and on vertically mount ed equipment. Duration: 2 hrs Objectives: Getting Started Review the basic types of shaft alignment . Describe the arrangement of dial indicators and t heir mount ing bracket s for a rim and face shaft alignment. Describe equipment checks and adjustments that are generally made before alignment readings are taken using the rim and face method. Aligning Horizontally Mounted Equipment Explain how to take measurements on horizontally mounted equipment for a rim and face alignment. Explain how to measure misalignment in the vertical plane using the rim and face met hod. Explain how to construct a graph representing misalignment in the vertical plane that is measured by the rim and face method. Describe how to correct a misalignment in the vertical plane. Explain how to measure misalignment on the horizontal plane using the rim and face met hod. Explain how to construct a graph representing misalignment in the horizontal plane that is measured by the rim and face method. Describe how to correct misalignment in the horizont al plane. Aligning Vertically Mounted Equipment Explain how to take measurements on vertically mount ed equipment for a rim and face alignment. Explain how to measure misalignment on vertically mounted equipment using the rim and face method. Explain how to construct graphs representing misalignment measured by t he rim and face method. Describe how to correct misalignment on vert ically mounted equipment.
Subjects: Getting Started Fundamentals General Preparations Aligning Horizontally Mounted Equipment Preliminary Measurements Vertical Plane Misalignment Horizontal Plane Misalignment Aligning Vertically Mounted Equipment Preparations Measuring Misalignment Correcting Misalignment Course 163 of 245
Maintenance
TOOLS: Introduction to Hand Tools (IHRDC_OM_AMTIH)
Overview: This interactive training unit is designed to familiarize trainees wit h the proper use of hand tools. After completing this unit , t rainees should be able to explain how to properly use hammers, punches, prying tools, screwdrivers, wrenches, measuring tools, cutting tools, vises and clamps. Duration: 2 hrs Objectives: Hammers, Punches, and Prying Tools Explain how to properly use a hammer. Describe the difference bet ween a claw hammer and a ball peen hammer. Explain how to properly use a sledgehammer. Explain how to properly use a wedge. Explain how to properly use a punch. Identify two types of punches. Explain how to properly use a ripping bar. Explain how to properly use a nail puller. Screwdrivers and Wrenches Explain how to properly use a screwdriver. Describe the difference between a straight-blade screwdriver and a Phillips-head screwdriver. Explain the proper use of non-adjustable, socket and torque wrenches. Measuring Tools Define t he terms level and plumb. Explain the proper uses of a level, a plumb bob and a chalk line. Explain how to properly use a framing square and a combination square. Explain how to properly use a steel rule, a measuring tape and a wooden folding rule. Cutting Tools Explain how to properly use a hand saw. Describe the differences between a crosscut saw and a rip saw. Explain how to properly use a file. Describe four types of files: a single-cut file, a double-cut file, a curved tooth file, and a rasp-cut file. Explain how to use a wire brush to clean tools such as files. Explain how to properly use a chisel. Distinguish between a wood chisel and a cold chisel. Explain how to properly use a ut ility knife. Gripping and Holding Tools Explain how to properly use slip joint, long nose, and lineman pliers. Explain how to properly use a bench vise and a C-clamp.
Subjects: Hammers, Punches, and Prying Tools Hammers and sledgehammers Wedges and punches Ripping Bars and nail pullers Screwdrivers and Wrenches Screwdrivers Wrenches and socket wrenches Measuring Tools Levels, plumb bobs and chalk lines Squares, rulers and measuring tapes Cutting Tools Saws, files and chisels Utility knives Course 164 of 245
Maintenance
TOOLS: Introduction to Power Tools (IHRDC_OM_AMTIP)
Overview: This interactive training unit is designed to familiarize trainees wit h the proper use of various t ypes of power tools. After completing this unit, t rainees should be able to explain how to properly use and maintain power drills, power saws, power grinders, jackhammers, and hydraulic jacks. Duration: 2 hrs Objectives: Types of Power Tools Ident ify and describe some common ways of classifying power tools. Ident ify and describe commonly used types of power drills. Ident ify and describe commonly used types of power saws. Ident ify and describe commonly used types of power grinders. Ident ify and describe common examples of jackhammers and hydraulic jacks. Power Tool Safety Describe safety procedures associated with the use of power tools in general. Describe safety procedures associated specifically with the use of electric power t ools. Describe safety precautions and procedures associated specifically wit h the use of pneumat ic power t ools. Power Tool Operation and Maintenance Describe the basic procedures for the safe operation and proper maintenance of different types of power drills. Describe the basic procedures for the safe operation and proper maintenance of different types of power saws. Describe the basic procedures for the safe operation and proper maintenance of different types of power grinders. Describe the basic procedures for the safe operation and proper maintenance of a t ypical jackhammer and a t ypical hydraulic jack.
Subjects: Types of Power Tools Power Tool Classifications Power Drills Power Saws Power Grinders Jackhammers and Hydraulic Jacks Power Tool Safety General Safety Concerns Electric Tool Safety Pneumatic Tool Safety Power Tool Operation and Maintenance Using Power Drills Using Power Saws Using Power Grinders Using Jackhammers and Hydraulic Jacks Course 165 of 245
Maintenance
TOOLS: Precision Measurement Instruments (IHRDC_OM_AMTMI)
Overview: This interactive training unit is designed to familiarize trainees wit h use of vernier calipers, different t ypes of micrometers, dial indicat ors, and fixed gauges. This program also describes basic calibrat ion procedures for several types of instruments and some basic guidelines for caring for precision measurement tools. Duration: 2 hrs Objectives: Vernier Caliper Ident ify the purpose and parts of a vernier caliper. Explain the procedures for using a vernier caliper properly. Demonstrate how to read a vernier scale. Micrometers Demonstrate the procedure for using an outside micrometer. Explain how to read an out side micrometer's scale. Demonstrate the procedure for using an inside micromet er. Demonstrate the procedure for taking measurements wit h a t elescoping gauge. Demonstrate the procedure for using a micrometer depth gauge. Dial Indicators Describe how to use a dial indicator. Fixed Gauges Explain how measurements are t aken with feeler gauges. Explain how measurements are t aken with a taper gauge. Calibration and Care Describe general procedures for calibrating several precision measurement instrument s. Describe some basic guidelines for caring for precision measurement tools.
Subjects: Vernier Caliper Basics Reading a Vernier Caliper Micrometers Out side Micrometers Inside Micrometers Telescoping Gauges Depth Micrometers Dial Indicators Features Fixed Gauges Feeler Gauge Taper Gauge Calibration and Care Calibration Care Course 166 of 245
Maintenance
VIBRATION ANALYSIS: Introduction (IHRDC_OM_AMVAI)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic principles associated with measuring and analyzing vibration in rotating equipment. After completing this unit, trainees should be able to explain what vibration is and why it occurs in rotating equipment. They should also be able to describe how to measure vibration using a transducer, a vibration meter, and a vibration analyzer. Additionally, t hey should be able to explain how t o analyze vibration using baseline data, vibration severity charts, and vibrat ion signatures. Duration: 2 hrs Objectives: Fundamentals Define vibration. Define t erms associated with vibration. Describe characteristics of rotating equipment that are associated with vibration. Describe causes of vibration in rotating equipment. Measuring Vibration Define t ransducer. Describe considerations associated with using a transducer. Describe how a typical vibration meter can be used in vibration analysis. Describe how a typical portable vibration analyzer can be used in vibration analysis. Describe how a typical computer-based vibration analyzer can be used in vibrat ion analysis. Analyzing Vibration Describe how informat ion about a vibration's characteristics can be used to analyze the vibration. Describe how baseline data can be used in vibration analysis. Describe how to use a vibration severity chart . Describe how a vibration signature can be used in vibration analysis.
Subjects: Fundamentals Charact eristics of Vibration Vibration and Rotating Equipment Measuring Vibration Basic Concepts Vibration Severity Charts Vibration Signatures Course 167 of 245
Maintenance
WELDING: Arc Welding (IHRDC_OM_AEEDC)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic concepts associated with arc welding. Aft er completing this unit, t rainees should be able to describe various hazards associat ed with arc welding and what can be done t o protect personnel from those hazards, identify and describe t he parts and operation of a basic arc welding machine, and describe basic tasks involved in preparing for a welding job. They should also be able to identify and describe the equipment used for three common arc welding met hods: shielded metal arc welding, metal inert gas arc welding, and tungsten inert gas arc welding. Duration: 2 hrs Objectives: Fundamentals Describe hazards associated with welding. Describe ways of providing basic prot ection to personnel from hazards associated with welding. Describe precautions t hat should be taken when an arc welding unit is set up. Describe the basic process of arc welding. Ident ify and describe the parts of a basic arc welding unit. Describe the basic operation of an arc welding unit. Describe basic tasks involved to prepare for a welding job. Welding Methods Ident ify and describe the equipment used for shielded metal arc welding. Ident ify and describe the equipment used for metal inert gas arc welding. Ident ify and describe the equipment used for tungsten inert gas arc welding.
Subjects: Fundamentals Safety Welding Equipment Preparations Welding Methods Shielded Metal Arc Welding Metal Inert Gas Welding Tungsten Inert Gas Welding Course 168 of 245
Maintenance
WELDING: Oxy-Fuel Gas Welding (IHRDC_OM_AMWIG)
Overview: This interactive training unit is designed to familiarize trainees wit h the basic parts and safe operation of oxy-fuel gas welding rigs. After completing this unit, trainees should be able to describe common oxy-fuel gas welding applications and safety concerns associat ed with the use of oxy-fuel gas welding equipment. They should also be able to describe the parts of a t ypical oxy-fuel gas welding rig and explain how t o assemble a rig, light the torch, and t hen disassemble the rig. Duration: 2 hrs Objectives: Basics Describe common oxy-fuel gas welding applicat ions. Describe characteristics of oxygen and acet ylene. Describe safety concerns associated with oxy-fuel gas welding and identify precautions that can be taken. Parts and Maintenance Describe characteristics of oxygen and acet ylene cylinders. State precautions associated with properly storing and transporting oxygen and acetylene cylinders. Describe oxygen and acetylene regulator types and gauges. State some basic guidelines for handling regulators. Describe oxygen and acetylene hoses. State some basic guidelines for handling hoses. Describe characteristics of welding and cut ting t orches and tips. Assembly, Lighting and Disassembly Describe tasks associated with assembling an oxy-fuel gas welding rig. Describe three types of oxy-fuel flames. Explain how to light a torch and adjust a flame. Describe a procedure for shut ting down and disassembling an oxy-fuel gas welding rig.
Subjects: Basics Applications Oxygen and Acetylene Safety Parts and Maintenance Assembly Lighting Disassembly Course 169 of 245
Subjects: Introduction to Pollution What is Pollution? Sources of Air Pollution Controlling Air Pollution Prevent ion Removal of Particulates Removal of Gases Course 170 of 245
Subjects: Introduction to Water Pollution Sources of Wat er Pollution Containment Wastewater Treatment Treatment Methods Filters Cooling Towers Waste Disposal Disposal Hazardous Waste Course 171 of 245
Subjects: Fire Basics Elements of Combustion Classes of Fires Extinguishers & Extinguishing Agents Water Multipurpose Dry Chemicals Carbon Dioxide Foam Class D Agents Extinguisher Identification Ident ification Symbols Pictures Course 172 of 245
Subjects: How Fires Start Basic Elements of Fire Igniting a Fire Preventing Fires Controlling Sources of Heat Controlling Sources of Fuel Managing Fire Situations Evacuation Procedures Emergency and Fire Prevention Plans Fire Types and Fire Extinguishers Using a Fire Extinguisher Using a Fire Hose/Standpipe System Course 173 of 245
Subjects: Structural Checks Preparation Major Components Safety Components Power System Checks Hydraulic System Electrical System Internal Combustion Engines Propane Gas Cylinders Operational Checks Before-Use Checks During-Use Checks Aft er-Use Checks Course 174 of 245
Subjects: Maneuvering a Forklift Rear Wheel Steering Turning a Corner Turning in an Aisle Turning Around Entering Trucks/Trailers/Rail Cars Driving on Slopes Elevators Traffic Safety Personal Preparedness In Case of a Tipover Pedestrians and Other Vehicles Obstacles and Hazards Parking a Forklift Handling Loads Visual Inspection Weights of Loads Preparing to Move a Load Moving a Load Placing a Load Disengaging t he Forks Other Considerations Course 175 of 245
Subjects: Forklift Basics How Forklifts are Powered Forklift Sizes and Capacit ies Forklift At tachments Forklift Components Major Sections of a Forklift Forklift Operating Controls Principles of Stability Three-Point Suspension Systems Center of Gravity Load Center Course 176 of 245
Subjects: Types of Hazards Physical Hazards Health Hazards Acute Effects Chronic Effects Operations and Emergency Response Standard Operating Procedures Emergency Response Plan Warning Labels Labeling Requirements NFPA Fire Diamond HMIS Labels Material Safety Data Sheets Types of Information Written Training Plan Requirements Types of Information Course 177 of 245
Subjects: What is HAZWOPER? What "HAZWOPER" Means Safety and Health Program Training Medical Surveillance Chemical Hazards Physical Hazards Health Hazards Rout es of Exposure Control Measures Engineering Controls and Work Practices Personal Protective Equipment Emergency Response Emergency Response Training Course 178 of 245
Subjects: Hazardous Materials What is a HAZMAT? Physical Hazards Health Hazards Hazardous Materials Emergencies Fire and Explosion Hazards Corrosive Mat erials Toxic Materials Hazards Not Directly Related to Chemical Hazards Identifying Hazardous Materials Recognizing Hazardous Materials Ident ifying Hazardous Materials First on the Scene First on the Scene - What to Do The Roles of a First Responder The DOT Emergency Response Guidebook Course 179 of 245
Subjects: Blood as a Hazardous Material What are Bloodborne Pathogens? HIV HBV The Risks of Occupational Exposure Healthcare Industry General Industry Other Exposure Risks Minimizing t he Risk of Occupational Exposure Rout es of Exposure Personal Protection Other Protective Measures The OSHA Bloodborne Pathogens Standard General Requirements Exposure Control Plan Exposure Incident Course 180 of 245
Subjects: Hazardous Noise Levels Sound Sound Waves Noise Action Level OSHA Standard Requirements Hearing Conservation Program Hearing Tests Hearing Protection Equipment Ear Plugs Ear Muffs Noise Reduct ion Rating Course 181 of 245
Subjects: Ergonomics Basics Musculoskeletal Disorders Ergonomics Explained Ergonomic Risk Factors Awkward Postures Force Repetition Contact Stress Vibration Static Postures Cold Temperatures Multiple Risk Fact ors Common MSDs Tendinitis and Tenosynovitis Carpal Tunnel Syndrome Epicondylit is Shoulder and Neck Pain Low Back Pain Raynaud's Phenomenon Recognize Signs and Symptoms of MSDs Controlling Ergonomic Hazards Job Hazard Analysis Things You Can Do to Reduce Ergonomic Hazards Course 182 of 245
Subjects: MSDS Overview What an MSDS IS Why an MSDS Is Important Product Ident ification Section Characteristics and Physical Hazards Chemical Ingredients Physical Data Fire and Explosion Data Reactivity Data Health Hazards Exposure Limits Rout es of Entry Effects of Exposure First Aid How to Protect Yourself Spills Waste Disposal Storage and Handling Course 183 of 245
Subjects: General Concerns Charact eristics of Liquids Handling Hazardous Mat erials Loading and Unloading Tank Truck Features Loading a Tank Truck Unloading a Tank Truck Course 184 of 245
Subjects: Classifications What are Hazardous Materials? Classes of Hazardous Materials Terms and Symbols Documentation and Packaging Documentation Packaging Labels Labels and Placarding Labels Course 185 of 245
Subjects: Overview Resource Conservat ion and Recovery Act OSHA Hazard Communication Standard DOT Regulations Examples of Warning Signs and Labels Hazardous Product Labels NFPA Hazard Rating System HMIS Rating System Shipping Labels DOT Shipping Labels and Markings Warning Signs Types of Information Protection Informing Workers Prevent ing Exposure Prevent ing Accident al Operation Tools Equipment Personal Gear Emergencies Aiding a Shock Vict im Fighting an Electrical Fire Course 186 of 245
Subjects: Fittings Proper Fit Fitt ing Factors Disposable Respirators Types of Disposable Respirators Selecting the Proper Size Ensuring the Proper Fit Fit Checks Checking General Condition Positive Pressure Check Negative Pressure Check Testing Qualitative Testing Quantitative Testing Course 187 of 245
Subjects: Protective Clothing Prot ective Clothing Wearing Clothing Properly Prot ecting Hands and Feet Protective Equipment Head Protection Eye Protection Hearing Protection Respiratory Protection Types of Respirators Fall Protection Fall Protection Equipment Course 188 of 245
Subjects: Air Purifying Respirators What is an Air Purifying Respirat or? Disposable Filter Masks Chemical Cart ridge, Filter and Canist er Masks Gas Masks Air Supplied Respirators What is an Air Supplied Respirator? Types of Air Flow Air Line Respirators SCBAs Port able Escape Respirators Use and Care of Respirators Selecting a Respirator Inspection Proper Use Cleaning and Disinfecting Reassembly and Testing Course 189 of 245
Subjects: Posture "Good Posture" Sitt ing Standing Walking and Turning Reaching Overhead Picking Up an Object from the Floor Safe Lifting "Mental Lifts" Lifting an Object Lowering an Object Carrying a Long Load Stacking a Load Turning a Valve Wheel Back Exercises At t he Office At Home or at the Gym Course 190 of 245
Subjects: Confined Space Characteristics Confined Spaces "Permit-Required" Confined Spaces Confined Space Hazards Hazardous Atmospheres Engulfment Hazard Configurat ion Hazard Other Hazards OSHA Confined Space Standard General Requirements Writt en Permit Space Program A Typical Entry Permit Protective Measures Preparing the Space Personal Protective Equipment Other Safet y Equipment The Attendant The Attendant's Responsibilities Course 191 of 245
Subjects: Understanding Motor Vehicle Accidents Typical fact ors in motor vehicle accidents The difference between "not at fault" and "accident-free" Defensive Driving Defensive driving defined Delayed start Changing lanes on a highway Space management defined Managing space in front Managing space t o the side and rear Space management when not moving Condition of the Driver Frustration and anger Rushing Distract ed Drowsy Alcohol Vehicle Condition and Safety Features Condition of the vehicle Safety belts Air bags Antilock braking systems Course 192 of 245
Subjects: Electrical Concepts Friend or Foe? Current Volt age Resistance Shock What is Shock? Amount of Current Length of Time Path Through the Body Effects Hazards High Voltage Area Overloaded Circuits Damaged Cords Bare Connect ors Long & Tail Objects Mobile Equipment Standing Water Protection Warning Tape, Signs, Locks and Tags Compressed Air Tools Battery Powered Tools Proper Grounding Emergencies Electrical Shock Victim Electrical Fire Course 193 of 245
Subjects: Introduction Conditions in Which Fall Protection Is Required Purposes of Fall Protection Basic Means of Achieving Fall Protect ion Fall Protection Training Fall Prevention and Fall Arrest Fall Protection Equipment Parts of a Typical Fall Arrest System Selection, Use and Care Selecting a Personal Fall Arrest System Using a Personal Fall Arrest System Caring for a personal Fall Arrest System Course 194 of 245
Subjects: Hazards in the Laboratory Physical Hazards Health Hazards Rout es of Exposure Minimizing the Risks Four Basic Safet y Principles Personal Protective Equipment The OSHA Lab Standard General Requirements The Chemical Hygiene Plan Chemical Hygiene Practices Safety Awareness Minimizing Exposure Chemical Storage General Storage Requirements Five Classes of Chemicals Emergency Emergency Response Plan Emergency Equipment/In Case of Exposure Course 195 of 245
Subjects: What is Lockout/Tagout? Accidents Guidelines Purpose, Scope and Benefits Hazardous Energy Types; Active Energy and Residual Energy Variations Effects Requirements Energy Cont rol Programs and Procedures Materials & Hardware Lockout/Tagout Procedures Training Inspection Procedure Shutdown and Removal of Energy Applying of Lockout/Tagout Devices Verification of Safe Condition and Preparation for Startup Removal of Lockout/Tagout Devices and Return to Service Special Situations Introduction Energizing Equipment Contract ors Group Lockout/Tagout Shift/Personnel Changes Course 196 of 245
Subjects: Safe Work Habits Fitness for Duty Housekeeping Tool Use Energy Sources Personal Protective Equipment Basic Types Specialized Types Hazard Communication Material Safety Data Sheets Warning Signs, Tags, and Labels Introduction t o HAZWOPER Fire Prevention Fire Safety Classes of Fire Extinguishers Course 197 of 245
Subjects: Primary Treatment Introduction t o Wastewater Wastewater Flow and Screening Equalization and pH Adjust ment Clarification Intermediate Treatment Chemical Precipitation Dissolved Air Flotation Secondary Treatment The Activated Sludge Process Sludge Handling Course 198 of 245
Subjects: Tertiary Treatment Filtration and Activated Carbon Adsorption Final Effluent Quality Standards Operator Responsibilities General Responsibilities Secondary Treatment Responsibilities Course 199 of 245
Subjects: Primary Water Treatment Introduction Screens Clarifiers Filters Chlorination Micro-Organisms Chlorine Addition Equipment Safety Precaut ions Course 200 of 245
Subjects: Dissolved Solids Removal Dissolved Solids Water Softeners Demineralizers Dissolved Gas Removal Dissolved Gases Carbon Filt ers Aerators De-aerators Chemical Treatment Chemicals in Water Treatment Chemical Safety Course 201 of 245
Control Systems
CONTINUOUS PROCESS: Field Devices: Analog Configuration (IHRDC_OM_ACPCA)
Overview: The CONTINUOUS PROCESS: Field Devices - Analog Configuration t raining program, or unit, is designed to familiarize trainees with basic procedures for configuring traditional and "smart" analog field devices. After completing this program, the trainees should be able to explain how to set zero and span and perform a calibration procedure on a traditional analog transmit ter. They should also be able t o explain the basics of how to configure a smart analog field device using a portable communicator or a laptop PC. Duration: 2 hrs Objectives: Define "analog" as it relates to process control signals. Explain how analog field devices function in process control systems. Explain how to set zero and span on a traditional electronic transmit ter. Explain how to perform a calibrat ion procedure on a non-smart transmitt er. Explain the relationship bet ween the value of a process variable and a transmitter's 4-20 milliamp output signal. Ident ify the basic configuration parameters for smart transmitters. Calculate a process measurement from a smart transmitt er's analog signal output. Explain how to configure a smart field devices with a port able communicator. Explain how to configure a smart field device with a laptop PC.
Subjects: Analog Field Devices Analog Field Devices Traditional Electronic Devices Configuring Smart Devices Configuration Methods Port able Communicators Laptop PCs Course 202 of 245
Control Systems
CONTINUOUS PROCESS: Field Devices: Analytical (IHRDC_OM_ACPAF)
Overview: The Field Devices - Analytical t raining program, or unit, is designed to familiarize trainees with input field devices t hat perform online analyses. After completing this program, the trainees should be able t o describe common applications and procedures t hat are associat ed with the use of online analyzers. They should also be able to describe some of the many different types of online analyzers that are used in cont inuous process systems. Duration: 2 hrs Objectives: Describe common applications of online analytical field devices in continuous process syst ems. Describe the essent ial component s of most online process analyzers. Describe general concerns associated with the installation, operation, and maintenance of online analyzers. Describe common types of electrochemical analyzers that use property- or compound-specific sensors for online analyses in continuous process syst ems. Describe one type of flammable vapor analyzer t hat is commonly used in continuous process systems. Describe common maintenance concerns associated with electromagnet ic analyzers. Describe optical analyzers that are commonly used for online analyses in continuous process syst ems. Describe mass spect rometers that are commonly used for online analyses in continuous process syst ems. Describe nuclear devices t hat are commonly used for online analysis of densit y. Describe common maintenance concerns associated with electromagnet ic analyzers. Describe chromat ographs that are commonly used for online analyses in continuous process systems. Describe common maintenance concerns associated with gas chromatographs.
Subjects: Introduction Typical Applicat ions Basic Concerns Types of Online Analyzers Electrochemical Analyzers Electromagnetic Analyzers Chromatographs Course 203 of 245
Control Systems
CONTINUOUS PROCESS: Field Devices: Configuring with a Laptop PC (IHRDC_OM_ACPCL)
Overview: The Field Devices - Configuring with a Laptop PC training program, or unit, is designed t o familiarize trainees with basic procedures for using a laptop PC t o configure analog field devices. After complet ing this program, the trainees should be able t o explain how to configure an input device such as a transmitt er and an output device such as a control valve. Duration: 2 hrs Objectives: Use Foxboro's PC-10 program to configure a transmitter. Use Foxboro's PC-20 program to configure a control valve.
Subjects: Configuring Input Field Devices Configuring a Transmit ter Configuring Output Field Devices Configuring a Control Valve Course 204 of 245
Control Systems
CONTINUOUS PROCESS: Field Devices: Digital Configuration with a DCS (IHRDC_OM_ACPCD)
Overview: The CONTINUOUS PROCESS: Field Devices - Digital Configurat ion with DCSs training program, or unit, is designed to familiarize t rainees with basic procedures for using a distributed control system (DCS) t o configure digital field devices. After completing t his program, the trainees should be able to explain how to use the Honeywell TDC 3000 and the Fisher-Rosemount DeltaV to configure a digital field device. Duration: 2 hrs Objectives: Explain how digital field devices differ from analog field devices. Describe how a DCS is used to monitor and cont rol a process. Ident ify and describe the information that is provided on t he point detail screens of a typical DCS. Describe a basic procedure for using a DCS to configure a digital field device. Describe the basic operating principles and architecture of fieldbus technology. Describe a basic procedure for using the DeltaV to configure a field device.
Subjects: The DCS Digital Field Devices Distributed Control Systems Honeywell TDC 3000 Point Details Configurat ion of Digital Field Devices Fisher Rosemount DeltaV Fieldbus Technology DeltaV Digital Configuration Course 205 of 245
Control Systems
CONTINUOUS PROCESS: Field Devices: Level and Flow (IHRDC_OM_ACPLF)
Overview: The Field Devices - Level and Flow t raining program is designed to familiarize trainees with input field devices that sense and monitor level or flow. After completing this program, the t rainees should be able to describe the basic operation of various t ypes of level measurement and flow measurement devices. Duration: 2 hrs Objectives: Define t he following terms: level, point level measurement, continuous level measurement, direct level measurement , and indirect level measurement. Ident ify common examples of point, continuous, direct, and indirect level measurement devices. Ident ify factors that determine the t ype of level measurement device used for a particular application. Define t he termsdensit y, specific gravity, and hydrost at ic pressure. Describe how pressure gauges, differential pressure transmitters, bubblers, and displacers provide level measurement s. Describe common applications and limitations associat ed with pressure gauges, differential pressure transmitters, bubblers, and displacers. Describe factors that must be considered during the configuration of pressure gauges, differential pressure transmitters, bubblers, and displacers. Describe how capacitance, or radio frequency (RF) devices, and conductance devices measure level. Describe common applications and limitations associat ed with capacit ance and conductance devices. Describe factors that must be considered during the configuration of capacit ance and conductance devices. Describe how radar, ultrasonic, laser, and nuclear level measurement devices work. Describe common applications and limitations associat ed with radar, ultrasonic, laser, and nuclear level measurement devices. Describe how tuning fork sensors and weight devices provide level measurement s. Describe common applications and limit at ions associated with tuning fork sensors and weight devices. Describe how different ial pressure flowmeters provide flow measurements. Identify common primary flow elements that are used in differential pressure measurement. Describe common problems that can affect the operation of differential pressure flowmeters. Describe how positive displacement flowmeters measure flow. Describe how turbine flowmeters measure flow. Describe applications and limitations associated with positive displacement flowmet ers and turbine flowmeters. Describe how magnetic, vortex, and ultrasonic flowmeters measure flow. Describe applications and limit at ions associated with magnetic, vortex, and ultrasonic flowmeters. Describe operating principles and applications, limitations, and inst allation considerations for Coriolis flowmeters and t hermal flowmeters.
Subjects: Level Measurement Types of Level Measurement Pressure- and Density-Based Devices Capacitance and Conductance Devices Non-Contact Devices Tuning Fork Sensors and Weight Devices Flow Measurement Different ial Pressure Flowmeters Mechanical Flowmeters Electronic Flowmeters Mass Flowmet ers Course 206 of 245
Control Systems
CONTINUOUS PROCESS: Field Devices: Pressure,Temperature & Weight (IHRDC_OM_ACPPT)
Overview: The Field Devices - Temperature, Pressure, and Weight t raining program, or unit, is designed to familiarize trainees with input field devices that sense and monitor temperat ure, pressure, or weight. After completing this program, the t rainees should be able to describe the basic operation of various types of temperature, pressure, and weight transducers and transmitt ers. Duration: 2 hrs Objectives: List typical t emperature, pressure, and weight applications. Explain how thermocouples, RTDs, and thermistors work. Explain reference junction compensat ion. Explain RTD lead length compensat ion. Explain how load cells work. Explain absolute, gauge, and differential pressure measurement. Explain the function of set points. Describe transmitter operating paramet ers, and define the following terms: range, LRL, URL, LRV, URV, span, turndown ratio, engineering units, PV, and SV. Explain how transmitter accuracy can be specified. Ident ify and describe common transmit ter configurat ion options. Describe the ways that transmitters communicate signal information. Describe how to set up a tradit ional t ransmitter. Explain how to communicate with, configure, and test a smart transmitter.
Subjects: Temperature, Pressure, and Weight Inputs Applications Temperature Transducers Pressure and Weight Transducers Sensor Swit ches Signal Equipment Transmitter Characteristics Transmitter Procedures Course 207 of 245
Control Systems
CONTINUOUS PROCESS: Field Devices: Using Field Communicators (IHRDC_OM_ACPFC)
Overview: The CONTINUOUS PROCESS: Field Devices - Using Field Communicators training program, or unit, is designed to familiarize t rainees with basic procedures for using field communicators to configure "smart " analog field devices. Aft er completing t his program, the trainees should be able to explain how to configure smart analog transmitters using a HART communicat or, a Honeywell communicator, a Yokogawa communicator, and the Foxboro Local Display Module. Duration: 2 hrs Objectives: Explain how to use the HART communicator to perform the basic configurat ion of a magflow transmit ter. Explain how to use a Honeywell SFC to perform the basic configurat ion of a differential pressure t ransmitter. Explain how to use the Yokogawa BT200 to perform the basic configuration of a pressure transmitter. Explain how to use the Foxboro Local Display Module to perform the basic configurat ion of a transmitt er.
Subjects: HART Protocol - Magnetic Flow Transmitter Using the HART Communicator Honeywell Protocol - Pressure (DP) Transmitter Using the Honeywell Communicator Yokogawa Protocol - Pressure Transmitter Using the Yokogawa Communicator Foxboro - Local Display Module Using the Foxboro Local Display Module Course 208 of 245
Control Systems
CONTINUOUS PROCESS: Introduction to Distributed Control Systems (IHRDC_OM_ACPID)
Overview: The Introduction to Distributed Control Systems training program, or unit , is designed to familiarize trainees wit h DCS architect ure and basic tasks that DCS technicians may be asked to perform. After completing this program, the trainees should be able to describe the architect ural organizat ion of DCS field components, central components, and control loops. They should also be able t o describe ways that a DCS technician typically works with a DCS. Duration: 2 hrs Objectives: Explain the functions of input and output devices. Describe the difference between digital and analog I/O devices. List examples of I/O field devices. Describe how I/O devices communicate. Ident ify I/O devices from a piping and instrument diagram. Describe typical I/O field termination equipment. Describe typical I/O and control processor cards and functions. Explain the data functions of t he system server. Explain how to use a DCS user interface for basic informat ion retrieval. Describe DCS networks. Explain why and how PLCs are sometimes part of a DCS. Describe typical control loops. Describe the information that can be obtained from loop sheets. Describe preparations for working on a field device. Describe basic service operations that may have to be performed on a field device. Ident ify troubleshooting tasks that can be performed in a rack room. Ident ify tasks that can be performed at a DCS user interface.
Subjects: DCS Architecture Field Components Central Components Control Loops Working with a DCS Field Device Tasks Rack Room Tasks At t he User Interface Course 209 of 245
Control Systems
CONTINUOUS PROCESS: Multiple Loop Control (IHRDC_OM_ACPML)
Overview: The Mult iple Loop Control training program, or unit , is designed to familiarize trainees wit h the basic operat ion and use of multiple loop control. After complet ing this program, the trainees should be able to explain the basic operation of multiple single loops, cascade cont rol, ratio control, feedforward control, and special connections that are used with multiple loop cont rol. They should also be able to use a P & ID to trace boiler control functionality. Duration: 2 hrs Objectives: Explain typical interactions between single control loops. Explain several types and applications of cascade control. Explain several types and applications of ratio control. Describe computational components that are typically used in multiple loop control. Explain how limiters, interlocks, override controls and selective controls are used. Explain the difference between feedback control and feedforward control. Describe the advantages, problems, and applications of feedforward control. Ident ify the main boiler control components and connections on a P & ID. Trace boiler control functionality.
Subjects: Multiple Loop Applications Multiple Single Loops Cascade Control Ratio Cont rol Special Multiple Loop Connections Feedforward Control Boiler Master Controls P & ID Conventions and Symbology Boiler Control Operation Course 210 of 245
Control Systems
CONTINUOUS PROCESS: Pneumatic Controls (IHRDC_OM_ACPPC )
Overview: The Pneumatic Controls training program, or unit, is designed to familiarize t rainees with the basic operation, maintenance, and calibrat ion of components in a pneumatic control system. After completing this program, t he trainees should be able describe to how to service the various devices that help dry and filter t he air and how to check pressure control devices in t he system for proper operation. They should also be able to describe t he basic operation and maintenance of some typical control components in a pneumatic syst em. Duration: 2 hrs Objectives: Describe the operation and maint enance of air supply components t hat dry and filt er compressed air in a pneumat ic cont rol system. Describe the operation and maint enance of pressure control components in a pneumatic control syst em. Describe the operating principles of pneumatic control components. Ident ify the basic types of pneumatic sensor-transmitters. Describe the operation and maint enance of sensor-transmitters. Ident ify and describe common types of pneumatic receiver-controllers. Describe basic calibration procedures for a typical receiver-controller. Ident ify and describe common types of pneumatic act uators. Describe procedures involved in testing, calibrating, and maintaining pneumatic actuators.
Subjects: Air Supply Maintenance Air Filtering Pressure Control Control Components Basic Operation Sensor-Transmitters Receiver-Controllers Actuators Course 211 of 245
Control Systems
CONTINUOUS PROCESS: Principles (IHRDC_OM_ACPCR)
Overview: The Principles training program, or unit , is designed to familiarize trainees wit h some of the basic material, process, and system characteristics that can affect process cont rol. After completing this program, the trainees should be able t o identify and describe some basic fact ors that affect process control. They should also be able to describe common process control methods and t he operat ion of loops that control critical process variables. Duration: 2 hrs Objectives: Ident ify variables that are routinely monitored and controlled by process control systems. Describe basic material properties and fluid flow charact eristics. Describe the relationship bet ween temperature and pressure in fluids. Describe the basic principles and methods of heat transfer. Ident ify and describe some basic factors that affect process control. Describe on/off, proportional, integral (reset), derivat ive (rate), and PID control algorithms. Ident ify and describe pressure, t emperature, level, flow, and pH control loops in a t ypical boiler system.
Subjects: Process Charact eristics Example System Layout Material Attributes Control Syst ems Basic Control Factors Process Control Methods Process Control Loops Course 212 of 245
Control Systems
CONTINUOUS PROCESS: Single Loop Control (IHRDC_OM_ACPSL)
Overview: The Single Loop Cont rol training program, or unit, is designed to familiarize trainees with the basic operation and use of single cont rol loops. After complet ing this program, the trainees should be able to explain the basic operation of a feedback cont rol loop, describe how t he proportional-integral-derivative (PID) control algorithm works, and ident ify and describe features that may be used to enhance the performance of a PID controller. Duration: 2 hrs Objectives: Describe a typical feedback control loop. Describe how the proport ional-integral-derivative (PID) cont rol algorit hm works. Ident ify and describe features that are commonly used t o enhance t he performance of a PID controller. Describe a typical single-loop pressure control system. Describe a typical single-loop temperature control system. Describe a typical single-loop level control syst em. Describe a typical single-loop flow control system. Describe a typical single-loop pH control system.
Subjects: Control Basics Feedback Control Loop PID Control Controller Enhancements Course 213 of 245
Control Systems
CONTINUOUS PROCESS: Smart Controllers (IHRDC_OM_ACPSC)
Overview: The Smart Controllers t raining program, or unit, is designed to familiarize trainees with the operation and use of smart controllers. Aft er completing t his program, the trainees should be able to describe basic procedures for installing, configuring, operating, and t uning smart controllers. Duration: 2 hrs Objectives: Describe the purpose of a smart controller. Describe a smart controller's common cont rol options. Explain how to install and wire a new or replacement smart controller. Explain how to configure a smart controller. Explain how to operate a smart controller. Explain how to tune a smart cont roller for optimum performance. Describe the procedures for troubleshooting a single loop process controlled by a smart controller. Describe the procedures for tuning a single loop process controlled by a smart controller.
Subjects: Setting Up Smart Controllers Charact eristics Installation and Configurat ion Using Smart Controllers Operation and Tuning Demonstration Course 214 of 245
Control Systems
CONTINUOUS PROCESS: Troubleshooting DCS I/Os: Practices (IHRDC_OM_ACPTP)
Overview: The Troubleshooting DCS I/Os: Practices t raining program, or unit, is designed to familiarize trainees with some practical applicat ions of basic procedures for troubleshoot ing the inputs and outputs of a distributed control system. After completing t his program, the trainees should be able to explain how to troubleshoot problems in digit al I/O devices that are part of a DCS, analog I/O devices that are part of a DCS, and miscellaneous I/O components of a DCS. Duration: 2 hrs Objectives: Describe basic steps for troubleshoot ing a problem in a digital I/O device that is part of a DCS. Describe basic steps for troubleshoot ing a problem in an analog I/O device that is part of a DCS. Describe basic steps for troubleshoot ing a problem in a miscellaneous I/O component of a DCS.
Subjects: Troubleshooting Practices Troubleshooting Digital I/O Devices Troubleshooting Analog I/O Devices Troubleshooting Miscellaneous I/O Components Course 215 of 245
Control Systems
CONTINUOUS PROCESS: Troubleshooting DCS I/Os: Procedures (IHRDC_OM_ACPTD)
Overview: The Troubleshooting DCS I/Os: Procedures training program, or unit, is designed to familiarize t rainees with basic procedures for t roubleshooting the input s and outputs of a distributed cont rol system. After complet ing this program, the trainees should be able to explain how to gather information about a DCS I/O problem, identify possible causes of the problem, test the possible causes, and finish up the troubleshooting procedure. Duration: 2 hrs Objectives: Explain how to gather information about a DCS I/O problem. Explain how to eliminate possible causes of a DCS I/O problem. Explain how to prioritize possible causes of a DCS I/O problem. Explain how to test possible causes of a DCS I/O problem in a logical order. Explain how to complete t he procedures for troubleshooting a DCS I/O problem.
Subjects: Troubleshooting Procedures Investigating Sympt oms Ident ifying Possible Causes Test ing Possible Causes Finishing Up Course 216 of 245
Control Systems
CONTINUOUS PROCESS: Troubleshooting Loops (IHRDC_OM_ACPTS)
Overview: The Troubleshooting Loops training program, or unit , is designed to familiarize trainees wit h basic procedures for troubleshooting cont rol loop problems. After completing this program, t he trainees should be able to explain how to use a syst ematic t roubleshooting procedure to t roubleshoot problems in control loops. Duration: 2 hrs Objectives: Explain how to gather information about a control loop problem. Explain how to eliminate components or functional elements as possible causes of a control loop problem. Explain how to prioritize possible causes of a control loop problem. Explain how to test possible causes of a control loop problem in a logical order. Describe the st eps that should be t aken to complete the troubleshooting of a control loop problem. Describe a basic procedure for troubleshooting a discrete control loop. Describe a basic procedure for troubleshooting a single analog control loop. Describe considerations in t roubleshooting a multiloop control system.
Subjects: The Troubleshooting Procedure Investigating Sympt oms Ident ifying Possible Causes Test ing Possible Causes Finishing Up Loop Troubleshooting Examples Discrete Loop Single Control Loop Multiloop Control Course 217 of 245
Control Systems
CONTINUOUS PROCESS: Tuning Loops (IHRDC_OM_ACPTL)
Overview: The Tuning Loops training program, or unit , is designed to familiarize trainees wit h the basic principles of t uning control loops. Aft er completing t his program, the trainees should be able to describe how t o prepare for tuning a loop and how t o tune a loop manually using a syst ematic trial and error method, t he Ziegler-Nichols open loop met hod, and the Ziegler-Nichols closed loop method. They should also be able describe how tuning can be accomplished by the auto-tune function, by art ificial intelligence feat ures, and by tuning software. Duration: 2 hrs Objectives: Describe tuning in relation to loop response. Describe the t ypes of process upsets. Explain process delays. Describe the effects of gain, reset , and rate on response curves. Explain how to identify and assess asymmetry, non-linearity, and noise. Explain how to correct or reduce hyst eresis, stiction, and noise. Distinguish between random tuning and systematic trial and error tuning. Describe the precautions necessary when tuning by trial and error. Explain the procedure for tuning using the Z-N open loop method. Explain the procedure for tuning using the Z-N closed loop, or ultimate gain, met hod. Describe how the auto-tune function tunes. Describe artificial intelligence (fuzzy logic) t uning features. Explain how to connect and run tuning programs. Describe the options tuning programs may provide.
Subjects: Closed Loop Operation Control Loop Response Before Tuning Manual Tuning Trial and Error Tuning Ziegler-Nichols Tuning Methods Automated Tuning Self-Tuning Software Tuning Course 218 of 245
Control Systems
CORE: Basic Electrical Test Equipment (IHRDC_OM_ACCBE)
Overview: The Basic Electrical Test Equipment training program, or unit, is designed to familiarize trainees with various types of electrical t est instruments. After complet ing this program, the trainees should be able to follow safe work pract ices and procedures while properly using circuit test ers, multimeters, ammet ers, megohmmet ers, and digital low resist ance ohmmeters. Duration: 2 hrs Objectives: Follow safe work practices and procedures while using electrical t est equipment . Use circuit testers t o indicate t he presence of energized elect rical circuit s. Use an analog mult imeter to measure voltage, resistance, and current in AC and DC circuits. Use a digital multimet er to measure voltage, resistance, and current in AC and DC circuits. Ident ify in-line and clamp-on ammeters. Use an analog ammeter to measure current through a conductor. Use a digital ammet er to measure current through a conductor. Use a megohmmeter t o test the insulation resistance of a conductor, transformer, and mot or. Explain how to measure the resistance of elect rical circuit s and equipment with a DLRO.
Subjects: Test Equipment Safety Safe Work Practices Circuit Testers Basic Operation Multimeters Basic Operation Ammeters Basic Operation Megohmmeters Basic Operation DLRO Basic Operation Course 219 of 245
Control Systems
CORE: Digital and Analog Oscilloscopes (IHRDC_OM_ACCDA)
Overview: The Digital and Analog Oscilloscopes training program, or unit, is designed t o familiarize trainees with the basic operation and use of digital and analog oscilloscopes. After completing this program, the trainees should be able to explain what an oscilloscope does, explain how to set up an oscilloscope for use, identify t he controls used to adjust an oscilloscope display, and explain how to use an oscilloscope t o make voltage measurements and time measurements. Duration: 2 hrs Objectives: Briefly explain how an oscilloscope converts a voltage input to an on-screen trace. Describe how an oscilloscope display is graduated. Explain why proper grounding is important. Explain how to set the controls to "standard position" for the initial setup of an oscilloscope. Explain how to select, compensate, and use oscilloscope probes. Ident ify the controls used to adjust an oscilloscope display and explain their functions. Explain what an oscilloscope's vertical controls do and how t o use them. Explain what an oscilloscope's horizontal controls do and how to use them. Determine an applied volt age by counting oscilloscope screen divisions. Determine frequency by measuring the period on an oscilloscope screen. Determine a pulse width and rise t ime.
Subjects: Fundamentals Basic Operating Theory Display Fundamentals Setting Up Grounding and Safety Controls Probes Control Use Display Vertical Horizontal Measurement Techniques Volt age Time Course 220 of 245
Control Systems
CORE: Introduction to Control and Data Systems (IHRDC_OM_ACCIC)
Overview: The Introduction to Control and Dat a Systems training program, or unit, is designed t o familiarize trainees with the role of information systems in plant operations and the elements of modern information systems. Aft er completing t his program, the t rainees should be able to identify the information needs of typical plant functional elements and explain how information gets into an information system. They should also be able to describe system architecture and explain how to use environment software and applicat ion software. Duration: 2 hrs Objectives: List the information needs of typical plant functional elements. Explain how alarms work in modern plants. List the routes by which information gets into the system. Explain I/O bus, LAN, WAN, client-server, and the role of network standards. Explain the function of an operating system. Describe the characteristics of common operat ing systems. Explain the role of operating system and network software. Explain virtual instrumentation. Explain programmable logic cont roller (PLC) program creation. Describe how to use graphical objects t o create t he system data structure and HMI. Describe password hierarchy and the need for security. Describe the functions and archit ecture of a SCADA syst em.
Subjects: Information and Plant Operations Information Needs Information Sources Information Systems System Architect ure Environment Soft ware Application Software Course 221 of 245
Control Systems
CORE: Introduction to Process Control (IHRDC_OM_ACCIN )
Overview: The Introduction training program, or unit, is designed t o familiarize trainees with the basic elements, t erminology, and functions of control systems. Aft er completing t his program, the trainees should be able to identify and describe various types of input and output devices that are commonly used with automat ed control systems. They should also be able to identify and describe common t ypes of control devices and control loop arrangement Duration: 2 hrs Objectives: Define t erms commonly associated with the input side of a control system. Ident ify and describe common types of temperature sensors that provide input information to a control system. Ident ify and describe common types of position sensors. Ident ify and describe common types of pressure sensors, flow sensors, and level sensors. Ident ify and describe common types of electric instruments, timers, counters, recorders, and pneumat ic sensors. Ident ify and describe common act uating devices used in the output side of a control system. Describe common decision-making devices that connect the input and output element s in a control system. Describe common control loop arrangements used in automatic control syst ems.
Subjects: Input Elements Terminology Temperature Sensors Position Sensors Pressure, Flow, and Level Sensors Other Input Devices Output Elements Actuating Devices Control Elements Decision-Making Devices Control Loops Course 222 of 245
Control Systems
CORE: Principles of Calibration (IHRDC_OM_ACCCA )
Overview: The Principles of Calibration t raining program, or unit, is designed to familiarize trainees with the basic principles associated with t he calibration of input field devices and control loops. Aft er completing t his program, the trainees should be able to explain how to test, adjust , and calibrate various types of gauges and transmitters. They should also be able to explain how to test , set up, and adjust input field devices and calibrate control loops. Duration: 2 hrs Objectives: Explain how to decide the best t ime to t est and calibrate. Describe the proper steps involved in a lockout/tagout procedure. Describe how to perform basic calibrat ion procedures on a typical pressure gauge, pressure transmit ter, and t hermocouple. Describe how to adjust a typical sensor that switches in response to discrete position. Describe how to test and adjust a typical sensor that switches at a temperature, pressure, or cont rol signal set point . Describe how to test and calibrate a typical sensor that responds t o concentrations. Describe how to test, set up, and adjust a typical sensor that responds to flow. Describe how to perform basic calibrat ion procedures on a typical output field device. Describe how to perform basic calibrat ion procedures on a typical cont rol loop.
Subjects: Gauges and Transmitters Preparation Pressure Gauge Pressure Transmitter Temperature Devices Field Devices and Control Loops Input Field Devices Out put Device and Loop Calibration Course 223 of 245
Control Systems
CORE: Principles of Control (IHRDC_OM_ACCCO)
Overview: The Principles of Control training program, or unit, is designed to familiarize trainees with t he basic operating principles of cont rollers used with discrete input/output devices and analog input/output devices. After completing this program, the t rainees should be able to explain the control logic used in syst ems with discrete (digital) I/O, describe how to troubleshoot systems that use individual relays and solid st at e controllers, and describe how t o program a PLC and troubleshoot PLC system problems. They should also be able to explain how analog variables can be converted to digit al data and vice-versa, describe PID cont rol, describe common controller options and applications, and describe how to diagnose problems in single and multiple cont rol loops. Duration: 2 hrs Objectives: Explain the cont rol logic used in systems with discrete (digital) I/O. Describe how to troubleshoot systems that use individual relays and solid state controllers. Describe how to program a PLC, test t he program, run and adjust the program, and troubleshoot PLC system problems. Explain how analog variables can be converted t o digital dat a and vice-versa. Describe proportional control, derivative cont rol, and integral control. Describe common controller options and applications. Diagnose problems in single and multiple cont rol loops.
Subjects: Controllers Used with Discrete I/O Digital Logic Individual Relays PLC Applications Controllers Used with Analog I/O Analog/Digital Conversion PID Control Special Controller Features Troubleshooting Control Loops Course 224 of 245
Control Systems
CORE: The Human-Machine Interface (IHRDC_OM_ACCHM)
Overview: The The Human-Machine Interface t raining program, or unit, is designed to familiarize trainees with the different types of HMIs t hat are likely t o be found in a modern plant . After completing this program, the trainees should be able t o obt ain process information using typical instrument s, operate typical switch controls, use smart I/O devices and controller interfaces, and perform common computer operations. Duration: 2 hrs Objectives: Read typical instruments. Use typical switch controls. Configure smart I/O devices. Operate portable instruments. Operate and program a variable frequency drive. Take readings from and program a loop cont roller. Use dedicated graphics terminals. Describe the role of soft ware in computer operation. Describe the main funct ional components of a computer. Use common DOS and character-based keyboard/screen functions. Use common GUI keyboard/screen functions. Turn a comput er on and log on. Find and run a program, enter data, save, print , exit , and shut down a computer.
Subjects: Traditional Equipment Interfaces Instrument s Controls Microprocessor-Based HMIs Smart I/O Interfaces Controller Interfaces The Computer Interface Basic Comput er Hardware and Operation The Human-Computer Interface Common Computer Operations Course 225 of 245
Control Systems
NETWORKS: Fiber Optic Systems (IHRDC_OM_ACNFO )
Overview: The NETWORKS: Fiber Optic Systems training program, or unit, is designed to familiarize t rainees with the basic operating principles of fiber optic syst ems and some of the basic installation and t esting methods. After completing this program, the t rainees should be able to describe characteristics of glass fibers and describe the function and types of fiber optic connectors. They should also be able t o describe basic procedures for installing and testing fiber optics. Duration: 2 hrs Objectives: Describe the composition of a common glass fiber. Describe characteristics of multi-mode fiber. Describe characteristics of single-mode fiber. Describe characteristics of optic fibers and cables. Describe the function and types of fiber optic connectors. Describe hazards and work precaut ions associated with fiber optics. List the main steps associated with running a new fiber optic drop. Describe steps that are commonly used to terminate fiber. Describe steps that are commonly used to make fiber splices. Describe steps that can be used to check newly inst alled fibers.
Subjects: Operating Principles Glass Fibers Basic System Hardware Installation Tasks Safety Installing Cable Terminations and Splices Course 226 of 245
Control Systems
NETWORKS: Introduction (IHRDC_OM_ACNIN )
Overview: The NETWORKS: Introduction training program, or unit, is designed to familiarize trainees with some different types of control systems and some basic concepts that apply to control system networks. After completing this program, the trainees should be able to describe the layout and operation of traditional non-networked control systems and the layout and operation of some common networked control systems. They should also be able t o describe factors that can affect the speed at which signals can be sent across a network, describe t he various levels of network protocol, and describe common physical network layouts, or topologies. Duration: 2 hrs Objectives: Describe the layout and operation of traditional non-networked control systems. Describe the layout and operation of some common networked control systems. Describe how informat ion is coded as digital data for network transmission. Ident ify and describe factors that can affect the speed at which signals can be sent across a network. Ident ify and describe the various levels, or layers, of network prot ocol (the rules t hat govern how a network functions). Ident ify and describe common physical network layouts, or topologies Ident ify common protocols used in network control systems.
Subjects: Control Systems Overview Non-Networked Syst ems Networked Systems Basic Network Concepts Digital Data Network Speed and Traffic Network Protocol and Topology Common Protocol Types Course 227 of 245
Control Systems
NETWORKS: Setting Up and Troubleshooting (IHRDC_OM_ACNST )
Overview: The NETWORKS: Sett ing Up and Troubleshooting training program, or unit, is designed to familiarize t rainees with basic concept s t hat apply to setting up and troubleshooting cont rol networks. After complet ing this program, the trainees should be able to describe different types of cables and connectors that are used t o link together devices in cont rol networks. They should also be able to describe basic procedures for installing, test ing, and troubleshooting control networks. Duration: 2 hrs Objectives: Describe coaxial cable and explain how to inst all a connector onto the cable. Describe common types of t wist ed pair cable and explain how to install connectors onto t he cables. Ident ify and describe factors that must be considered when cable is rout ed. Describe how to connect and use a cable test er to perform various tests on network cabling. Describe common hardware configuration procedures that need to be performed during network installation. Describe common troubleshooting techniques that are helpful for ident ifying problems with network cabling and devices.
Subjects: Cables and Connectors Coaxial Cable Twisted Pair Cable Network Installation Cable Routing Circuit Testing Hardware Configuration Troubleshooting Course 228 of 245
Control Systems
PLCs: Architecture, Types and Networks (IHRDC_OM_ACLAT)
Overview: The PLCs: Architecture, Types and Net works t raining program, or unit, is designed to familiarize trainees with the basic operation and components of programmable logic controllers (PLCs). After completing this program, the trainees should be able t o explain what a PLC does, identify and describe PLC components, and explain how PLCs communicate. Duration: 2 hrs Objectives: Explain how PLCs can be used to replace conventional, hard-wired ladder diagrams. Explain how PLC programs can be used to cont rol machines and processes. Ident ify the three main part s of a PLC system. Recognize a processor for a PLC and describe its functions. Recognize different types of input modules. Explain how to wire input devices int o input modules. Recognize different types of out put modules. Explain how to wire out put devices into output modules. Recognize power supplies. Recognize different types of programming terminals. Ident ify the three main time periods of the PLC scan cycle. Ident ify factors that can affect the scan cycle time of a PLC. Recognize different types of PLC networks. List devices that typically communicate across different types of PLC networks. Recognize that automated net works may include methods of machine cont rol other than PLCs.
Subjects: PLC Operations Basic PLC Concepts System Components The Processor The Input System The Output System Other Components The PLC Scan The PLC Scan Cycle Scan Time How PLCs Communicate Networking PLCs Other Methods of Machine Control Course 229 of 245
Control Systems
PLCs: Human Machine Interface and Troubleshooting (IHRDC_OM_ACLMT)
Overview: The PLCs: HMIs and Troubleshooting training program, or unit , is designed to familiarize trainees wit h human-machine int erfaces and how they can be used in the troubleshoot ing of programmable logic controller system problems. After completing this program, the trainees should be able to identify various t ypes of HMIs and explain how t hey are connected and used. They should also be able to describe the five st eps of troubleshooting and explain how t o use those steps and an HMI to t roubleshoot a problem in a PLC system. Duration: 2 hrs Objectives: Ident ify common types of HMIs. List different ways to connect an HMI to a PLC. Describe some basic factors involved in using a PC-based HMI. Explain why it is important to know the equipment before you start to troubleshoot. List the aids available to you in investigating the symptoms. Explain how to use the half-splitting method of identifying symptoms. Explain how to prioritize and eliminate possible causes. Explain the importance of determining root causes of malfunct ions. Explain how to use an HMI and the five-step troubleshoot ing process to troubleshoot a PLC-cont rolled system.
Subjects: The Human-Machine Interface Types of HMIs Connection to the PLC Using an HMI The Five Steps of Troubleshooting Know the Equipment Investigate Symptoms List Probable Causes Test Probable Causes Discover Root Causes A Troubleshooting Case Study Course 230 of 245
Control Systems
PLCs: I/O Communication (IHRDC_OM_ACLIO)
Overview: The PLCs: I/O Communication training program, or unit, is designed t o familiarize trainees with the various ways in which real-world devices can be connected to t he input and out put systems of a programmable logic controller. After completing t his program, the trainees should be able to identify various t ypes of I/O modules and field devices, and explain how direct I/O connect ions are made. They should also be able to ident ify some common device networks and ident ify some devices, ot her t han PLC devices, that you might find on a t ypical device network. Duration: 2 hrs Objectives: Ident ify the pieces of hardware that make up a PLC rack. Different iate between serial and parallel communication between racks. Ident ify the three types of I/O modules. Describe a typical I/O addressing scheme. Describe the differences between discret e, or bit, devices; word devices; and analog field devices. Describe the difference between sinking and sourcing I/O modules. Explain why proper fusing, shielding and grounding are important when field devices are wired. Relate I/O modules to the input and output image tables, and t o the scan cycle. Ident ify some common proprietary and non-proprietary device networks. Ident ify some devices, ot her t han PLC devices, that you might find on a t ypical device network.
Subjects: Direct I/O Connections How I/O Modules Are Mounted I/O Module Types I/O Module Addressing Field Devices Field Wiring I/O Data Processing Networked I/O Modules Types of Device Networks Devices Course 231 of 245
Control Systems
PLCs: Installing and Maintaining (IHRDC_OM_ACLIM)
Overview: The PLCs: Inst alling and Maintaining t raining program, or unit, is designed to familiarize trainees with the basic procedures involved in installing and setting up PLC equipment. After completing this program, the trainees should be able to explain how t o mount and wire up PLC hardware. They should also be able to describe how to establish communications between a PC and a PLC, clear the processor memory, and initially configure the processor. Duration: 2 hrs Objectives: Describe what must be taken into consideration when mounting PLC hardware. Describe how to connect various types of PLC power supplies. Explain why emergency stop circuits must be hardwired. Explain what to be aware of when populating PLC chassis. Describe what to be aware of when wiring I/O field devices. Describe what to be aware of when making network connections. Explain how to establish communication between a PLC and a PC. Explain the st eps necessary to clear the memory of a PLC. Explain the st eps necessary to perform t he initial configurat ion of a PLC.
Subjects: Installing the PLC Mounting PLC Chassis Power Supplies and Connections E-Stop Circuits Configuring and Populating the Chassis I/O Wiring Network Connections Initial Configuration Establishing Communications Clearing Memory Performing Initial Configuration Course 232 of 245
Control Systems
PLCs: Introduction to Programming (IHRDC_OM_ACLIP)
Overview: The PLCs: Int roduction to Programming training program, or unit, is designed to familiarize trainees with t he basics of programming a programmable logic controller. After completing this program, the trainees should be able to ent er a simple ladder diagram program into the memory of a PLC. Duration: 2 hrs Objectives: Explain how to start programming software and verify proper drivers, connections, and node addresses. Name the two main file t ypes in PLC memory. Explain how to clear PLC memory. Ident ify PLC bit and word I/O addresses. Explain how to use RSLogix to insert a rung into a PLC. Ident ify input and output inst ructions and explain how to add t hem to a rung. Explain how to use RSLogix to add instruct ions and branches to a rung in a PLC. Different iate between the inst ructions for a discret e input device and the inst ructions for input-type contact s on an output device. Different iate between the inst ructions for real I/O devices and the instructions for virtual I/O devices. Explain how to connect real, discrete I/O devices to a PLC. Explain how to determine input and output addresses for PLC screw terminals. Explain how to use RSLogix to program a PLC to emulat e a hard-wired program.
Subjects: Establishing Communications Programming wit h a PC The PLC Memory Model Preparing to Program the PLC Programming a Rung Basic Rung Using Discrete I/O Complex Rungs Complex Discret e I/O Inst ructions A Real System Example The Hardware The PLC Program Course 233 of 245
Control Systems
PLCs: Ladder Logic and Symbology (IHRDC_OM_ACLLL)
Overview: The PLCs: Ladder Logic and Symbology training program, or unit, is designed to familiarize t rainees with how PLCs use ladder diagrams and what the symbols used on ladder diagrams mean. Aft er completing t his program, the trainees should be able to identify common ladder diagram symbols, explain how a ladder diagram rung performs t he logic functions necessary to determine whether the rung is true or false, and interpret the meaning of some common PLC instructions. Duration: 2 hrs Objectives: Ident ify the major parts of a ladder diagram. Describe how a ladder diagram forms a parallel circuit. Ident ify the NEMA symbols for common input devices. Ident ify the NEMA symbols for common output devices. Different iate between the Boolean AND, OR and NOT functions for multiple devices on a rung. Ident ify how each rung performs the logic functions necessary to determine whet her t he rung is t rue or false. Recognize rung numbers on a ladder diagram. Interpret cross references on a ladder diagram. Explain the PLC mode of operation with the Run-Rem-Prog key switch in each of it s positions. Ident ify the typical symbols used in a PLC ladder program and explain the function of mnemonics. Ident ify each of the three parts of the PLC scan cycle. Interpret the meaning of some common complex instructions. Ident ify several things that may interrupt the normal scan cycle.
Subjects: The Ladder Diagram Rung The Ladder Diagram as a Parallel Circuit Ladder Diagram Symbols Multiple Devices on a Rung Complete Ladder Diagrams The Mult iple Rung Control Program Rung Numbers and Cross References Ladder Logic Execution PLC vs. Hardwired Program Execution Complex Instructions Interruptions to the Scan Cycle Course 234 of 245
Control Systems
PLCs: Numerics (IHRDC_OM_ACLNU)
Overview: The PLCs: Numerics t raining program, or unit, is designed to familiarize trainees with numbering syst ems and codes commonly used by programmable logic controllers (PLCs). After complet ing this program, the trainees should be able to int erpret place values for decimal, binary, octal, and hexadecimal numbers and convert numbers from one numbering syst em t o another. They should also be able to explain what BCD and ASCII codes are and how they are used. Duration: 2 hrs Objectives: Ident ify commonly used numbering systems. Explain the organization of a positional numbering system. Interpret place values for binary numbers. Describe ways t hat signed binary numbers may be represented in a PLC. Convert bet ween binary and decimal numbers. Interpret place values for octal numbers. Convert bet ween octal, binary, and decimal numbers. Interpret place values for hexadecimal numbers. Convert bet ween hexadecimal, octal, binary, and decimal numbers. Explain what BCD code is. Express and int erpret information in BCD code. Explain what ASCII code is.
Subjects: Numbering Systems Numbering System Basics Positional Systems Binary Numbering Place Values Signed Binary Numbers Conversions Octal Numbering Place Values Conversions Hexadecimal Numbering Place Values Conversions Codes BCD Code BCD Conversions ASCII Code Course 235 of 245
Control Systems
PLCs: Program Entry, Testing and Modification (IHRDC_OM_ACLPE)
Overview: The PLCs: Program Entry, Test ing, and Modification training program, or unit, is designed to familiarize t rainees with the t echniques used t o install, t est, and modify a PLC program, or project. After completing this program, the t rainees should be able to explain how to prepare a system for program entry and how to download or enter the program. They should also be able to explain how to test and debug t he program and make changes to the program in various processor modes. Duration: 2 hrs Objectives: Explain how to establish communication between a PLC and a PC. Explain the st eps necessary to clear the memory of a PLC. Explain how to install a project in a PLC. Explain some common techniques used in test and debug operations. Explain what must be done when a PLC's hardware or software configuration is changed. Explain how to use the PLC EEPROM for program backup. Explain how to use a PC hard drive for program backup. Explain the differences between online and offline programming. Describe the process for changing the PLC program while the system is in the program mode. Describe the process for changing the PLC program while the system is in the run mode.
Subjects: Entering and Testing the Program Preparing for Program Ent ry Downloading or Entering a Project Test ing and Debugging Configuration and Program Changes Configurat ion Changes Uploading and Downloading Projects Changes While in Program Mode Changes While in Run Mode Course 236 of 245
Control Systems
PLCs: Programming Common Functions (IHRDC_OM_ACLCF)
Overview: The PLCs: Programming Common Functions training program, or unit, is designed to familiarize t rainees with the basics of programming common functions for a programmable logic cont roller. After completing this program, the trainees should be able to identify common non-I/O PLC inst ructions and explain how they are used. Duration: 2 hrs Objectives: Different iate between bit addresses and word addresses. Explain the function of each part of a timer. Explain the function of each part of a counter. Explain how to use word addresses to send data t o and from analog I/O modules. Explain how program control instructions modify the normal program scan sequence. Explain how immediate instructions interrupt the normal program scan cycle. Explain how data comparison instructions are used to make program decisions. Explain how math instructions are used t o perform calculat ions and modify data. Explain how regist ers and sequencers are used to emulate motor-driven cam switches. Explain how file instructions are used to move and manipulate data. Explain the operating concept of a PID feedback loop. Explain how to connect real, word I/O devices to a PLC. Explain how to use RSLogix to program a PLC with some common functions.
Subjects: Simple Word Instructions Word Addresses Timers Counters Analog I/O Program Control Instructions Modifying the Scan Sequence Modifying the Scan Cycle Comparison and Math Instructions Data Comparison Instructions Math Instructions Data Manipulation Instructions Registers and Sequencers File Instructions PID Loop Instruction A Real System Example The Hardware The PLC Program Course 237 of 245
Control Systems
PLCs: Troubleshooting Hardware (IHRDC_OM_ACLTH)
Overview: The PLCs: Troubleshoot ing Hardware training program, or unit, is designed to familiarize t rainees with tools and procedures for t roubleshooting hardware-related PLC problems. After completing this program, the trainees should be able to explain how t o isolate a PLC problem to either hardware or software and network and how to use PLC hardware indicat ors, programming software, and appropriate test equipment t o troubleshoot processor faults and I/O problems. Duration: 2 hrs Objectives: Explain how to isolate a problem to hardware vs. software and net work. Explain how to identify a software and network problem. Explain the meanings of common processor indicators. Describe common I/O problems. Ident ify the troubleshoot ing aids commonly found on a PLC power supply. Ident ify the indicators commonly found on a PLC processor module. Ident ify the indicators commonly found on a PLC I/O module. Explain how to go on-line using RSLogix. Explain how to use common search functions. Explain how to force an input or output instruction. Describe how cross references and I/O monitors can be used in troubleshooting. Ident ify the three main part s of a typical I/O system. Different iate between test equipment that is and is not appropriate for t roubleshooting PLC syst ems. Use the appropriate programming software and test equipment to troubleshoot a typical input system. Use the appropriate programming software and test equipment to troubleshoot a typical output syst em.
Subjects: Isolating PLC Problems Isolating the Problem Software and Net work Problems Hardware Problems Hardware Indicators Power Supply Processor I/O Modules Troubleshooting with Programming Software Starting t he Soft ware Using the Search Functions Using the Force Functions Using Cross References and I/O Monitors Troubleshooting I/O Systems I/O System Organization Using Test Equipment on I/O Syst ems Troubleshooting an Input Syst em Troubleshooting an Output System Course 238 of 245
Control Systems
PLCs: Troubleshooting Software and Networks (IHRDC_OM_ACLSN)
Overview: The PLCs: Troubleshoot ing Software and Networks training program, or unit, is designed to familiarize trainees with how t o use PLC programming software t o isolat e soft ware and network problems. Aft er completing t his program, the trainees should be able to go on-line to connect to a PLC network and be able to identify and describe the major parts of the PLC memory and some memory prot ection options. They should be able to explain how to diagnose timer, count er, and sequencer problems and how to use PLC indicators, processor status information, TND and SUS instructions, Custom Data Monitors, and histograms to t roubleshoot software problems. They should also be able to explain how to use processor indicators and communications software t o isolat e network problems, how to isolate network media problems, how to find and fix a network configuration problem, and how to connect to a PLC across a network and then troubleshoot a problem. Duration: 2 hrs Objectives: Explain how to start software and select drivers. Explain how to use a browser t o connect to a stand-alone or networked PLC. Describe the major parts of the PLC memory. Describe some major memory protection options. Explain how to use the five-step troubleshoot ing process to troubleshoot a PLC-cont rolled system. Explain how to isolate a problem to software and network vs. hardware. Explain how to isolate a problem to software vs. network. Explain how the fault indicat ion in the processor status box can be used for troubleshooting. Explain how to use processor status t able information to isolate problems. Explain how to check I/O configuration. Explain how to use the TND and SUS instructions to monit or program control instructions. Explain how to diagnose timer, count er, and sequencer problems. Explain how to use the Custom Data Monitor. Explain how to use histograms. Explain how to isolate a problem to a specific network node on DH+. Explain how to isolate a problem to a specific network node on Rem I/O. Explain how to isolate an HMI communication problem. Explain how to isolate net work media problems. Explain how to find and fix network configuration problems. Explain how to connect to a PLC across a network. Explain how the key switch affects programming across a net work.
Subjects: Connecting to the PLC Network Starting t he Soft ware Examining t he PLC Memory Troubleshooting Software Problems Isolating Problems Using PLC Status and Configuration Files Program Control Problems Timer, Counter, and Sequencer Problems Using Data Monitors Troubleshooting Network Problems Isolating the Problem Problems wit h Network Media Problems wit h Network Configuration Troubleshooting PLCs Across a Net work Course 239 of 245
Control Systems
VARIABLE SPEED DRIVES: Applications (IHRDC_OM_ACVDA)
Overview: The VARIABLE SPEED DRIVES - Applicat ions training program, or unit , is designed to familiarize trainees wit h common applicat ions of variable speed drives and basic procedures for variable speed drive installat ion. After completing this program, t he trainees should be able to describe ways in which variable speed drives are used and ways in which t hey are set up and t ested. Duration: 2 hrs Objectives: Ident ify common applications for variable speed drives. Describe typical network configurations for drives Ident ify common problems associated wit h the installation of variable speed drives. Set up a variable speed drive for operation. Test the operation of a variable speed drive. Create checkpointing documentation for a variable speed drive installation.
Subjects: Common Applications Selecting Drives Networking Drives Ident ifying Problems VSD Installation Set ting Up Test ing the Set up Creating Checkpointing Course 240 of 245
Control Systems
VARIABLE SPEED DRIVES: Controllers and Troubleshooting (IHRDC_OM_ACVCT)
Overview: The VARIABLE SPEED DRIVES: Controllers and Troubleshooting training program, or unit, is designed to familiarize t rainees with general procedures for using a variable speed drive cont roller to troubleshoot system problems and for troubleshooting problems in the controller itself. After completing this program, t he trainees should be able to describe how to safely use a variable speed drive controller t o locate basic system problems. They should also be able to explain how to use a test point checklist to troubleshoot a variable speed drive controller and how to test the major component s of t he controller. Duration: 2 hrs Objectives: Describe safe work practices for troubleshooting a variable speed drive. Ident ify and describe the four basic cat egories of electrical test equipment. Explain how to use a controller display to locate operat ing problems in a variable speed drive. Explain how to set up, interpret, and use a key test point checklist to troubleshoot a variable speed drive controller. Explain how to check the major components of a variable speed drive controller.
Subjects: Troubleshooting with the Controller Safety Basics Common Drive Problems Troubleshooting the Cont roller Test Point Checking Component Checking Course 241 of 245
Control Systems
VARIABLE SPEED DRIVES: Introduction to VSDs (IHRDC_OM_ACVSD)
Overview: The Introduction to Variable Speed Drives training program, or unit , is designed to familiarize trainees wit h the operation and use of variable speed drives. Aft er completing t his program, the trainees should be able to identify different types of DC and AC drives and explain how they cont rol mot or operation. Duration: 2 hrs Objectives: Ident ify different types of variable speed DC drives. Explain the operation of a DC motor controlled by a variable speed controller. Ident ify the major component s of a variable speed controller operating a DC motor. Explain the operation of a variable speed controller operating a DC motor. Ident ify different types of inverter drives. Explain the operation of a AC motor controlled by an inverter. Ident ify the major component s of a PWM invert er operating an AC motor. Explain the operation of a PWM inverter operating an AC mot or. Ident ify the major component s of a flux vector drive. Explain the operation of an AC mot or controlled by a flux vector drive. Ident ify different types of flux vect or drives. Explain the operation of a flux vector drive.
Subjects: DC Drives Control of DC Motors DC Controller Component s DC Controller Operation Inverter Drives Inverter Control of AC Motors AC Inverter Components PWM Controller Operat ion Flux Vector Drives Flux Vector Control of AC Motors Flux Vector Controller Operation Course 242 of 245
Control Systems
VARIABLE SPEED DRIVES: Programming Controllers (IHRDC_OM_ACVPC)
Overview: The VARIABLE SPEED DRIVES: Programming Controllers training program, or unit, is designed t o familiarize trainees with the basic principles of programming controllers for variable speed DC and AC motors. After completing this program, the t rainees should be able to identify and describe common parameters that may have to be programmed for a DC variable speed controller and for an AC variable speed controller. They should also be able to describe additional programming that may be required when an AC variable speed controller is set up for flux vector operat ion. Duration: 2 hrs Objectives: Ident ify and describe common paramet ers that may have to be programmed during the setup of a DC variable speed drive controller. Ident ify and describe common paramet ers that may have to be programmed when configuring the I/O for a DC variable speed drive controller. Ident ify and describe common paramet ers that may have to be programmed in order to monitor the operation of a DC variable speed drive cont roller. Ident ify and describe common paramet ers that may have to be programmed during the setup of an AC variable speed drive controller. Ident ify and describe common paramet ers that may have to be programmed when configuring the I/O for an AC variable speed drive controller. Ident ify and describe common paramet ers that may have to be programmed in order to monitor the operation of an AC variable speed drive controller. Describe additional programming that may be required when an AC variable speed cont roller is set up for flux vector operation.
Subjects: Programming DC Controllers Set up I/O Configurat ion Monitoring Programming AC Controllers Set up I/O Configurat ion Monitoring Flux Vector Programming Course 243 of 245
Control Systems
VARIABLE SPEED DRIVES: System Troubleshooting (IHRDC_OM_ACVST)
Overview: The VARIABLE SPEED DRIVES: System Troubleshoot ing training program, or unit, is designed to familiarize trainees with the use of a basic five-step troubleshooting method to troubleshoot a variable speed drive system. After completing this program, the t rainees should be able to describe problems associated wit h a variable speed drive system's motor, wiring, and electrical supply. They should also be able to describe each step of the five-step troubleshoot ing process and explain how to use t hose st eps to troubleshoot a problem in a variable speed drive system. Duration: 2 hrs Objectives: Explain how to locate and correct loose motor connections. Explain how to detect conditions that could lead to motor winding failure, and suggest remedies for those condit ions. Explain how to detect conditions that could lead to motor bearing failure, and suggest remedies for those conditions. Explain how to detect motor leakage currents, and suggest remedies for the problem. Explain how to locate and correct loose wiring connections. Ident ify and suggest modifications to variable speed drives affected by improper shielding and grounding. Explain how to check and monitor cont rol system feedback. Ident ify and suggest modifications to variable speed drives affected by overvoltage reflect ions. Explain how to locate and correct loose wiring connections. Ident ify and suggest methods for correcting voltage imbalance in variable speed drive systems. Explain how to detect single phasing in variable speed drive applications. Explain how to detect harmonic anomalies, and suggest remedies for those conditions. Explain why it is important to know the equipment before you start to troubleshoot. List the aids available to you in investigating the symptoms. Explain how to identify probable causes. Explain how to prioritize probable causes. Explain why it is important to determine the root causes of malfunctions. Explain how to use the five-step troubleshoot ing met hod t o troubleshoot a variable speed drive.
Subjects: Troubleshooting a VSD System Troubleshooting the Motor Troubleshooting the Wiring Troubleshooting the Electrical Supply Five-Step Troubleshooting Method Know the Equipment Investigate Symptoms List Probable Causes Test Probable Causes Discover Root Causes Troubleshooting Case St udy Course 244 of 245
Control Systems
VARIABLE SPEED DRIVES: Systems and Integration (IHRDC_OM_ACVSI)
Overview: The VARIABLE SPEED DRIVES: System Int egration t raining program, or unit, is designed to familiarize trainees with several common ways in which variable speed drives and automated systems are linked together. After completing this program, the t rainees should be able to describe how variable speed drives are integrated into distributed control systems and programmable control systems. They should also be able to describe the operation of tachometers, encoders, and resolvers, and explain how to inst all field devices for variable speed drives. Duration: 2 hrs Objectives: Describe how variable speed drives are integrated into distributed control systems. Ident ify the net work connect ions between a variable speed drive and a distributed control system. Explain how to install a variable speed drive in a distributed control system. Describe how variable speed drives are integrated into programmable control systems. Ident ify the net work connect ions between a variable speed drive and a programmable control syst em. Explain how to install a variable speed drive in a programmable control syst em. Describe the operation of a tachometer used to cont rol a variable speed drive. Explain how to install and set up tachometers for variable speed drives. Describe the operation of an encoder used to control a variable speed drive. Explain how to install and set up encoders for variable speed drives. Describe the operation of a resolver used to cont rol a variable speed drive. Explain how to install and set up resolvers for variable speed drives. Explain how to install field devices for variable speed drives.
Subjects: Control System Integration DCS Integrat ion PLC Int egration Feedback and Field Device Integration Tachometers Encoders and Resolvers Field Devices Course 245 of 245