Public Program: Maintenance Technology

 

Alignment Principles And Technology-MTT1400

OBJECTIVE
• The principle objective of this course is to educate the participants in the principle of alignment , preparation prior to performing shaft alignment , measuring techniques and calculating by using various alignment methods to ensure smooth operation and minimize equipment / machinery parts problem.

COURSE CONTENTS
• Introduction to alignment
• Why driver and driven machines need alignment?
• When the correct alignment occurs ?
• Which machine arrangement require accurate alignment?
• What can be reduce by correct alignment ?
• Alignment Fundamentals
• Types of misalignment
• Alignment plane
• Measuring tools
• Selection of alignment procedure
• Sweep reading
• Moveable machine movement
• Shims
• Pre Alignment Check
• Sag
• Soft foot
• Run out
• Mechanical looseness
• Motor magnetic
• Piping strain
• Alignment Method
• Rim and face method (close type coupling )
• Rim and face method (spacer type coupling )
• Reverse indicator method
• Computerize alignment
• Laser alignment
• Tolerance
• Soft foot suggested tolerance
• Misalignment suggested tolerance for short coupling types.
• Misalignment suggested tolerances for coupling spacer .
• Thermal growth & Hot Alignment Check
• Causes of thermal expansion
• Desired reading
• Performing hot alignment

WHO SHOULD ATTEND
• All level of technicians , supervisor and engineers who are involve directly or indirectly in performing Shaft Alignment as well as those who are interested to deepen their knowledge about the subject.

DURATION : 3 Days
TIME : 9.00 am – 5.00 pm
VENUE : JOHOR SKILLS
METHODOLOGY : Lecture, hands-on, open discussions, video presentation, practical demonstration


 

Maintenance And Servicing Steam Boiler-MTT1300

OBJECTIVE
• To enable the participants to explain aspects related to maintenance of steam including boiler fundamentals, maintenance procedure, repair procedure as well recommended guidelines for care of steam boilers.

COURSE CONTENT
INTRODUCTION TO BOILERS
• Types of boiler
• Boiler fundamental
• Application of boilers
BOILER WATER QUALITY
• The importance of boiler water treatment
• Problems associated with water quality
• Control of internal chemical conditions
• Water treatment plant.
BOILER COMPONENTS
• Essential fittings
• Boiler auxiliaries
INTRODUCTION TO BOILER MAINTENANCE
• Maintenance in general
• Routine maintenance
• Periodic maintenance
• Critical maintenance
INSPECTION AND MAINTENANCE
• Preparation for inspection
• Carrying out boiler inspection
• Care and maintenance
• Boiler repairs
• Maintenance program
WELDING AND NON-DESTRUCTIVE TESTING
• Welding processes
• Control of welding activities
• Types and application of NDT
MAINTENANCE OF BOILER CONTROLS EQUIPMENT
• Indicators and recorders
• Controls and interlocks
PREVENTING BOILER FAILURES
• Operational aspects
• Maintenance aspects
• Other causes
QUIZ AND TEST

WHO SHOULD ATTEND
• Safety Officers, Safety Professional, Plant Supervisors Senior Technicians, Engineering Assistants and individual involved is related field.

DURATION : 4 Days
TIME : 9.00 am – 5.00 pm
VENUE : JOHOR SKILLS
METHODOLOGY : Lecture, hands-on, open discussions, video presentation, practical demonstration


 

Advanced Boiler Technology-MTT1200

OBJECTIVE
• To enable the participants to enhance their skills and knowledge on the operation procedures of boiler as well as identifying types and its related design

COURSE CONTENT
INTRODUCTION
• Types of boiler
• Boiler design
• Boiler efficiency
BOILER OPERATION
• Pre-operation
• Start0up procedure
• In service operation
• Out of service operation
BOILER WATER QUALITY
• The importance of boiler water treatment
• Problems associated with water quality
• Control of internal chemical conditions
• Water treatment plant
BOILER CONTROL
• Indicators and recorders
• Controls and interlocks
INSPECTION AND MAINTENANCE
• Preparation for inspection
• Carrying out boiler inspection
• Care and maintenance
• Boiler repairs
• Maintenance program
INTRODUCTION TO WELDING
• Welding processes
• GTAW and SMAW processes
• Control of welding activities
INTRODUCTION NDT
• Dye penetrant
• Magnetic particles
• Radiography
• Ultrasonic
QUIZ AND TEST
PRACTICAL AND SITE VISIT

WHO SHOULD ATTEND
• Safety Officers, Safety Professional, Plant Supervisors Senior Technicians, Engineering Assistants and individual involved is related field.

DURATION : 3 Days
TIME : 9.00 am – 5.00 pm
VENUE : JOHOR SKILLS
METHODOLOGY : Lecture, hands-on, open discussions, video presentation, practical demonstration


 

Basic Boiler Technology-MTT1100

OBJECTIVE
To enable the participants to understand the followings :-
• Basic principles of boilers
• Classification and types of boiler
• Procedures in boiler maintenance operation.

COURSE CONTENT
INTRODUCTION
• History of boiler
• Application of boiler
• Boiler fundamentals
RELEVENT ACT AND REGULATIONS
• Occupational Safety and Health Act
• Factories and Machinery Act
PRINCIPLES OF BOILER OPERATION
• Preparing for operation
• Starting up
• On line operation
• Out of service operation
BOILER WATER QUALITY
• The importance of boiler water treatment
• Problems related to water quality
• Internal water treatment
BOILER COMPONENTS
• Essential fittings
• Boiler auxiliaries
INTRODUCTION TO BOILER MAINTENANCE
• Maintenance in general
• Routine maintenance
• Periodic maintenance
• Critical maintenance
PREVENTING BOILER FAILURES
• Overpressure
• Weakening of structure
• Operation of combustion equipment
• Furnace explosion
• Furnace implosion
QUIZ AND TEST
PRACTICAL AND SITE VISIT

WHO SHOULD ATTEND
• Safety Officers, Safety Professional, Plant Supervisors Senior Technicians, Engineering Assistants and individual involved is related field.

DURATION : 3 Days
TIME : 9.00 am – 5.00 pm
VENUE : JOHOR SKILLS
METHODOLOGY : Lecture, hands-on, open discussions, video presentation, practical demonstration


 

Oil Analysis And Proactive Maintenance-MTT1000

OBJECTIVE
• To equip participants with a firm foundation in the theory and practice of Lube Oil Analysis and Contamination Control

COURSE CONTENT
• Lubrication Fundamentals
• Functions
• Types
• Base Oils & Additives
• Lubrication Regimes
• Maintenance Strategies
• Intro to Greases
• Wear Mechanisms
Component :
• Bearing
• Gears
• Cylinders
Systems :
• Engines
• Hydraulics
• Turbines
• Compressors
• Contamination Control
• Contaminant Types & Effect
• Common Modes of Ingress
• ISO Cleanliness Code & NAS Classes
• Monitoring Contaminants
• Contamination Control Strategies
• Oil Analysis Basics
• Objectives of Oil Analysis
• 3 Areas of Oil Analysis
• Base Oil Degradation & Additive Depletion
• Wear Particle Analysis
• Test Methods & Instruments
• Setting & Monitoring Target Oil Cleanliness Levels
• Introduction to Diagnostics & Interpretation
• Best Sampling Practices
• Principles & Importance of Obtaining a Good Representative Sample
• Sampling Frequency
• Primary & Secondary Sampling Points
• Sampling Location & Fittings
• Sampling Tools & Accessories
• Sampling Procedure

DURATION : 3 days
TIME : 9.00 am – 5.00 pm OR 6.00 PM – 10.00 PM
VENUE : JOHOR SKILLS
METHODOLOGY : Lecture, hands-on, open discussions, video presentation, practical demonstration


 

Basic Vibration Analysis-MTT900

OBJECTIVE
• Upon completion of this course, the successful candidate will be able to describe the key components of accurate, repeatable data collection using appropriate tools and measurement criteria; detect the presence of machinery vibration problems; and identify the probable cause of most common machinery vibration problems. This course and exam meet the requirements of the American Society of Nondestructive Testing (ASNT) Vibration Level I Certification.

COURSE CONTENT
• Machinery Vibration
• Vibration Motion
• Basics of Machinery Vibration Measurement
• Instrument Types and Limitations
• Vibration Transducers
• Condition Monitoring of Basic Machines
• Vibration Diagnosis
• Data Collection
• Data Collection Setup
• Unbalance
• Misalignment
• Detection of Rolling Element Bearing Faults
• Safety and Health

WHO SHOULD ATTEND
• Technicians, Supervisors and Machine Engineering Assistants and all those who are involved and responsible for the planning, design and maintenance for electrical machines.

DURATION : 3 Days
TIME : 9.00 am – 5.00 pm
VENUE : JOHOR SKILLS
METHODOLOGY : Lecture, hands-on, open discussions, video presentation, practical demonstration


 

Compressor Maintenance-MTT700

Objective
• The course is designed to equip the participant with the basic knowledge of compressor operations, troubleshooting and maintenance. The participant must be able to learn the objective of reliability of compressors and its degradation towards cost. The goal of any well-run maintenance organization is to have the lowest cost of the sum of two quantities, i.e. :
• Maintenance labor and material; and Production loss (which includes lack of ability to produce, and value added material that is lost as a result of a break down) reduction resulting from an inadequate maintenance program.

Course contents
Overview
• Compressor function in the system
• Types of compressor
• Prime movers
Compressors
• Construction
• Size, speed, cycle and efficiency
• Lubrication systems and oils
Compressor and System-Related Problems
• Lubrication
• Liquid flood back
• High head pressure
• Low suction pressure
• Refrigerant charge
• Superheat
• Low head pressure
• High suction pressure
Compressor Components
Related Safety Practices
• Refrigerant pressure
• Value spring pressure
• Testing pressure
• Prime mover isolation
• Tool safety
Compressor Control and Protection Devices
• High and low pressure controls
• Oil failure control
• Internal relief value
• Motor starters and overload
• Internal motor temperature sensors
• Crankcase heaters
Use of Manufacturers Manual
• Procedures and specifications
• Wear tolerances
• Parts lists
Compressor Inspection
• Preparing Compressor and area for Teardown
• Disassembly and inspection
• inspection of internal parts
• Main bearing replacement
Compressor Start-Up
Compressor Preventative Maintenance
• Importance of Preventative Maintenance
• Procedures common to most compressors.

Who Should Attend
• Technicians and Engineers

Duration : 3 days
Time : 9.00 am – 5.00 pm
Venue : JOHOR SKILLS
Methodology : Lecture, hands-on, open discussions, practical demonstration


 

Pump Maintenance-MTT600

Objective
• This course is designed to provide the participant with an understanding of the fundamentals of pump design and operation and equipment maintenance. Topics will include basic pump style and operating characteristics. Pump maintenance requirements will be discussed that includes removing, disassembling, inspecting, repairing and reassembling various pumps.

Course Contents
1. Introduction to good Maintenance
2. Types of Pump Design
• Theory
• Classification
• Operation
3. Pump disassembly
• Set-up
• Disassembly
• Cleaning & Inspection
• Talking of ìas foundî Measurements
• Talking & Recording Measurements
• Equipment History
4. Pump Repairs
• Repair Methods and Procedures
• Repair by Replacement
5. Pump Assembly
• Set-up
• Bearing Installation
• Gaskets
• Mechanical Seals
• Packing & Packing Adjustments
6. Post Repair Testing
• Acceptance Tests
• Performance Testing
7. Course Conclusion
• Round Table Discussions
• Course Critique

Who Should Attend
• Technicians, Supervisors and Maintenance Personnel.

Duration : 3 days
Time : 9.00 am – 5.00 pm
Venue : JOHOR SKILLS
Methodology : Lecture, hands-on, open discussions, practical demonstration


 

Bearing Maintenance-MTT500

OBJECTIVE
• To enable the participants to:-
• Identify the various types of bearing and their application
• Identify the type of fit and tolerance required in a particular bearing application.
• Perform mounting and dismounting of bearings using cold and hot mounting process.
• Able to state the various types of bearing failure, remedies and maintenance.
• Able to know the type of lubrication and lubricating methods.

COURSE CONTENTS
1. Bearing and application knowledge
• Basic bearing designation system.
• Types of bearing.
• Bearing internal clearance.
• Fits and tolerances.
2. Mounting and dismounting of bearings
• Principles of mounting and dismounting.
• Mechanical, Thermal and Hydraulic methods and tool for mounting and dismounting of various bearing types.
3. Maintenance and damage preventation
• Bearing lubrication
• Function of lubrication.
• Oil and grease.
• Relubrication interval and quantity.
• Reasons for bearing failure
4. Predictive maintenance
• Basic concept.
5. Workshop practical
• Mounting and dismounting of bearing
• on cylindrical shaft seating.
• on taper shaft seating.
• with adapter sleeve.
• with withdrawl sleeve.
6. Method
• Mechanical.
• Thermal.
• Hydraulic.

DURATION : 2 Days
TIME : 9.00 am – 5.00 pm
VENUE : JOHOR SKILLS
METHODOLOGY : Lecture, hands-on, open discussions, video presentation, practical demonstration


 

Lubricants And its Applications-MTT400

OBJECTIVE
• To achieve the goals of a good lubrication programme in plant maintenance.

COURSE CONTENTS
1. General theory
• Formation of lubricants
• Formation of lubricant film
2. Types of lubricants
• Fluid lubricants
• Greases
• Solid thickeners
3. Lubricant characteristics
• Oil properties
• Grease properties
4. Additives used in lubricating oils
4.1 Lubricants selection
• General selection guidelines
4.2 Daily lubrication management
• Enforcement of lubrication management
• Lubricant check
Checking
• Trouble check for lubrication
• Lubrication trouble practices and countermeasures

METHODOLOGY
• A participative and interactive approach using group discussions, role presentation, live video, slide and lectures.

WHO SHOULD ATTEND
• Maintenance Technicians, Mechanics, Supervisors, Foremen and Production Personnel.

DURATION : 2 day
TIME : 9.00 am – 5.00 pm
VENUE : JOHOR SKILLS
METHODOLOGY : Lecture, hands-on, open discussions, video presentation, practical demonstration


 

Effective Equipment Management System-MTT300

OBJECTIVE
• To provide an effective equipment management system that will give an edge on cost, quality and delivery of product/services.
Key Benefits :-
• Highly motivated workforce for implementing a maintenance program
• Direct and immediate implementation to your workplace
• Learn the latest in maintenance management today

COURSE CONTENTS
OVERVIEW
• Objective of maintenance system
• The trend today
• How maintenance has changed
• Factors in maintenance
• Benefits of an effective maintenance program
TOWARDS EFFECTIVE MAINTENANCE
• TPM overview
• Overall equipment effectiveness
• TPM activities
• 6 majors losses
MAINTENANCE SYSTEM
• Scope of maintenance department
• Maintenance types defined
• PM Defined
• Justification for PM program
• Maintenance system flowchart
PM SYSTEM – I
• Concept of PM
• Main section of PM
• Design of checklist, schedule
• Group activities
COMPUTERIZED SYSTEM
• CMMS overview
• How to justify?
• Factors to select
• CMMS and predictive maintenance
• Demonstration
EQUIPMENT IMPROVEMENT
• Sporadic VS Chronic equipment failures
• Ways to prevent sporadic failures
• Techniques to remove chronic failures
PM SYSTEM – II
• Getting started
• Systems setup
• ID coding
• Group activity
IMPLEMENTATION
• Steps to implementation
• Hindrances to implementation
• Rules for successful implementation
• Milestone chart

WHO SHOULD ATTEND
• Plant Managers, Maintenance Managers, Maintenance Planners, Plant Engineers and Officers involved in plant and equipment selection, Plant Installation, Project Management and maintenance of equipment and facilities.

DURATION : 2 days
TIME : 9.00 am – 5.00 pm
VENUE : JOHOR SKILLS
METHODOLOGY : Lecture, hands-on, open discussions, video presentation, practical demonstration


 

Planning For Computerized Maintenace Management System-MTT200

Objectif
• Computerized Maintenance Management System (CMMS) is among the most sigificant and far-reaching development affecting plant services today. It significant the productivity and efficiency of plant services departments.

What You Will Learn
• Understand the importance for planned maintenance
• Appreciate the use of CMMS in the enhancement of productivity and quality and / or to the contribution of quality and productivity improvement.
• Have clear understanding of the basic requirements for the successful implementation of CMMS in an organisation.
• Know how to select and justify a computerized maintenance system for an organisation.
• Exposure to practical sessions with emphasis on hands-on experiences to stimulate the implementation of CMMS.

Course Content
1.Introduction
• What is planned maintenance ?
• Why it is needed ?
• The breakdown philosophy
• Preventive maintenance
• Condition-based maintenance
• Computerized maintenance
• Benefits of CMMS
• Who uses it ?
2. CMMS
• An overview
• Hardware and software
• How to justify ?
• How to select ?
• Rules for successful implementation
• CMMS and Predictive Maintenance
3. Detail consideration in CMMS
• Equipment information
• Equipment ID
• Job procedures
• Frequency of schedules
• Date/meter -based schedules
• Automatic scheduling
• Manpower
• Work orders
• Spare parts
• History records
• Reports
4. Case studies of CMMS
• Manufacturing
• Plant engineering
• Service industry
• Property/building maintenance
5. Demonstration of CMMS
• Using computer simulation
6. How to organise a CMMS
• A review of a manual system
• Migration to CMMS
– hardware and software selection
– some golden rules
7. Setting up a system
• Data collection
• ID coding
• Job order coding
• Multiple scheduling
• Date/meter-based scheduling
8. Computerization
• Entering the data
• Generate weekly schedule
• Generate historical reports
• Corrective action request
• Manpower management
• Works order system
9. Parts Inventory Control
• A review of a computerized inventory system
• A review of how spare parts control is linked to CMMS
• Implement a parts inventory
• Generate reports
• Purchasing/budget control
10. Workshop
• Group discussion and workshop on how to setup and implement a CMMS in the participantsí work place.

Who Should Attend
• Plant Managers, Maintenance Managers, Maintenance Planners, Plant Engineers and Officers involved in plant and equipment selection, plant installation, project management and maintenance of equipment and facilities.

Duration : 2 Days
Time : 9.00 am – 5.00 pm
Venue : JOHOR SKILLS
Methodology : Lecture, hands-on, open discussion, video presentation, practical demonstration


 

Machine Maintenance (Mechanical)-MTT100

Objective
• To provide participants with the ability to acquire practical knowledge in machine maintenance and diagnose defects in related machine parts.

Course Content
• Introduction to good Maintenance
• Productive Maintenance
• Machine Elements : screw, chain, belt, roller, bearing, key and shaft.
• Lubricant and Lubrication Management
• Disassembly and Assembly
Workshop Practical
• Disassembly and Assembly of machines
• Mounting and Dismounting of bearing

Who Should Attend
• Technicians, Supervisors and maintenance personnels.

Duration : 5 Days
Time : 9.00 am – 5.00 pm
Venue : JOHOR SKILLS
Methodology : Lecture, hands-on, open discussions, practical demonstration

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