Mechanical maintenance skills

Introduction
The following course has been designed to give electrical maintenance staff a knowledge of mechanical skills. It is designed to run in twenty days, two x ten day sessions. This course has been specifically designed for an NHS trust. We can of course customize a course especially for your company requirements.
Objectives
By the end of each session, participants will be able to:
One day Session on Health & Safety Issues.

• State the general Health & Safety issues surrounding working on Mechanical systems, including: Health and Safety at Work Act 1974, PPE Regulations, Manual Handling Regulations, Abrasive Wheels Regulations, Gas Safety Regulations, Pressure Regulations, Permit to Work, System Isolation and draining to make safe.

Two day Session on Drives and Lubrication.

• Identify types of lubrication, oil and grease applications, why lubrication is changed, Hazards associated including personal hygiene
• Identify types of belt drive, safety considerations when working with belt drives, guards, defects and faults likely to be found, Correctly replacing belts including alignment, tensioning techniques.
• Identify drives and couplings, including selection, advantages of different types, alignment techniques and guarding.
• Practical - Session on belt alignment and tensioning, Coupling alignment.

Four day Session on Basic Pipework

• Identify types of steel pipework, grades, dimensions and their applications.
• Understand methods of cutting and forming steel pipework. BSP threads: how they are cut by hand and by machine.
• Identify malleable iron, wrought iron, steel and welding fittings - their use and application.
• Understand flanges: identification of imperial and metric, use of flange tables.
• Identify types of copper pipework, grades, dimensions and their applications.
• Understand methods of cutting and forming copper pipework.
• Identify copper fittings, Compression, capillary brass and copper.
• Understand jointing methods and procedures - mechanical and using heat: soft solder, silver solder and braze.
• Have an understanding of installation techniques, pipe size, flow characteristics, laying to fall, rising to vent, expansion.
• Practical - To construct a simple pipework circuit using copper and steel pipework and fittings and hydraulically test for integrity on completion. Cut Flange joint etc. from sheet jointing. Carry out nut and bolt exercise to confirm tightening techniques/patterns. Pack valve and pump glands. Thread identification - metric, UNC, UNF, BSW, BSF, BSP.

Three day Session on Low Pressure Hot Water Heating Systems

• Understand low pressure hot water heating systems (LPHW), the component parts and purpose behind regulating and balancing a system.
• Have an understanding of a vented and an unvented system.
• Understand the need for insulation.
• Have a basic understanding of boilers - LPHW gas and oil burners and Calorifiers - storage, non storage and plate.
• Understand statutory inspections.
• Understand types, benefits and applications.
• Understand maintenance considerations and requirements.
• Practical - to include site visit to familiarize participants with plant and equipment. Removal and replacement of radiator valves. Removing and replacing a radiator in system. Replace a section of steel and copper pipework within a LPHW system. Identify on site, Building services controls including: Capillary control, actuator types, programme control (BMS, Optimizers etc)

One day Session on Hot Water Systems (DHW)

• Understand hot water systems (DHW)
• Understand DHW flow and return, primary and secondary service.
• Understand source of DHW and how it is incorporated into the system.
• Understand primary and secondary circulation pumps
• Identify types of materials, pumps, valves, compounds used.
• Understand about Legionella and the New Model Water Bylaws.
• Understand the need for insulation.
• Practical - Inspect local site installations.

One day Session on Cold Water Systems

• Understand cold water systems, mains drinking water and tank fed down service (MCW) and CWDS.
• Have an understanding of The New Model Water Bylaws.
• Understand typical installations.
• Understand the reasons for break tanks.
• Identify types of materials, valves and compounds used
• Understand about Legionella and Chlorination.
• Understand the need for insulation.
• Practical - Inspect local site installations.

One day Session on Taps

• Understand different types of tap and water temperature controls.
• Understand the maintenance of the common types of tap - seat and gland.
• Understand the techniques in removing/replacing of taps, waste outlets etc.
• Understand the maintenance of cisterns/wwp's
• Practical - To strip, re-seat, re-washer, re-pack a selection of taps. To overhaul a toilet cistern.

Two day Session on Drainage

• Have an understanding of the different types of plastic pipework, grades, dimensions and applications.
• Understand consideration for expansion.
• Identify plastic fittings, types, their use and method of assembly, push, mechanical, heat.
• Understand above ground drainage systems - foul and rainwater.
• Identify types of materials used, with particular regard for correct material selection in hazardous area's, e.g. laboratories.
• Understand reasons for optimum fall on pipework
• Understand venting of systems.
• Understand maintenance considerations to clear blockages etc. clearing eyes.
• Identify types of sanitary ware
• Understand drain clearing techniques.
• Understand procedures for clearing blocked toilets, basins, sinks etc.
• Practical - Assembly exercise using 1½" plastic waste pipework and fittings. Clearing blockages from toilets, basins and foul drains. Inspection of site services and installations.

Three day Session on Steam

• Have a basic understanding of steam boilers, how they operate and raise steam.
• Identify and understand the operation and maintenance of steam boiler mountings.
• Understand the statutory requirements
• Understand basic water treatment.
• Have a basic understanding of burner types, fuels and combustion.
• Understand the principles of steam, the steam and condensate cycle.
• Understand steam distribution.
• Understand pressure controls and diagnostics.
• Understand steam trapping and venting.
• Understand the concept of condensate recovery.
• Understand and be able to identify steam trap by selection.
• Understand temperature control.
• Practical - Visit local plant areas and familiarize participants with the plant, inspect dismantled traps, controls, etc.

One day Session on Air Conditioning and Ventilation Overview

• Be familiar with air conditioning and ventilation plant and system components.
• Understand plant maintenance requirements, filters, checking temperatures, airflow, etc.
• Understanding of a simple refrigeration cycle and how that process is incorporated into a full air conditioning system, e.g. operating theatres.
• Practical - familiarization with local plant.

Last day
Final Assessments and Review of Training.
Certification
Course programme includes Practical and Written Assessments Those reaching the required standard will receive a certificate.