silibus a18 (l3)

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TEKNOLOGI MINYAK & GAS [ MECHANICAL PLANT - DOWNSTREAM ]

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Edisi Pertama September 2014

Institusi Latihan Jabatan Tenaga Manusia

http ://www.jtm.gov.my/kurikulum

Hak Cipta Terpelihara. Dokumen ini diklasifikasikan sebagai TERHAD. Tidak dibenarkan

mengeluar mana-mana bahagian dalam kandungan Sukatan Latihan dalam apa jua bentuk

tanpa keizinan daripada Jabatan Tenaga Manusia (JTM).

SUKATAN LATIHAN: A18 SIJIL TEKNOLOGI MINYAK DAN GAS ( MECHANICAL

PLANT – DOWNSTREAM ) SEMESTER 3 merupakan dokumen yang menggariskan

perkara-perkara yang perlu diperolehi oleh seorang graduan di dalam bidang kemahiran

Teknologi Minyak dan Gas ( Mechanical Plant – Downstream ). Sukatan latihan ini

dibangunkan mengikut format Institusi Latihan Jabatan Tenaga Manusia (ILJTM) dan telah

mengambil kira Standard Kemahiran Pekerjaan Kebangsaan (National Occupational Skill

Standard – NOSS) serta Kurikulum Unit Kompetensi (Curriculum of Competency Unit -

CoCU) daripada Jabatan Pembangunan Kemahiran (JPK) iaitu perubahan dokumen yang

berasaskan Unit Kompetensi (CU) dan Aktiviti Kerja (WA) yang memenuhi standard

persijilan kemahiran Malaysia.

Kod Pengesahan Sukatan Latihan : SFB/A18/92014

Tarikh Pengesahan Sukatan Latihan : 00 SEPTEMBER 2014

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PENGESAHAN JAWATANKUASA PEMANDU KURIKULUM JTM

KLUSTER PEMBUATAN

Dengan ini dimaklumkan bahawa silibus Kluster Pembuatan bagi kursus peringkat Sijil

Teknologi Minyak Dan Gas (Mechanical Plant - Downstream) telah disemak dan

disahkan dalam Mesyuarat Jawatankuasa Pemandu Kurikulum JTM Bil. 6/2013 yang

diadakan pada 04 Disember 2013 di Bilik Mesyuarat Utama JTM, Putrajaya. Sehubungan

itu, silibus yang telah disahkan ini hendaklah digunapakai bermula 04 Disember 2013

diseluruh ILJTM.

....................................................

(MOHD NUZI BIN YAACOB)

Pengerusi Kluster

............................................................................

(SYED MOHAMAD NOOR BIN SYED MAT ALI)

Pengerusi Mesyuarat

Jawatankuasa Pemandu Kurikulum

KANDUNGAN

1. PENDAHULUAN .............................................................. Error! Bookmark not defined.

1.1. Pengenalan .............................................................. Error! Bookmark not defined.

1.2. Objektif ............................................................... Error! Bookmark not defined.

1.3. Pra-syarat ............................................................... Error! Bookmark not defined.

1.3.1.Kemasukan ke Semester 1 .............................................................................. i

1.4. Tempoh Latihan ....................................................... Error! Bookmark not defined.

1.4.1.Kemasukan ke Semester 1 .............................. Error! Bookmark not defined.

1.5. Kaedah Latihan ........................................................ Error! Bookmark not defined.

1.5.1.Struktur Silibus ................................................. Error! Bookmark not defined.

1.5.2.Struktur Rujukan NOSS ................................... Error! Bookmark not defined.

1.6. Peluang Kerjaya ....................................................... Error! Bookmark not defined.

2. AHLI JAWATANKUASA ............................................................................................ v

3. SEMESTER 1 ................................................................... Error! Bookmark not defined.

3.1. Carta Profil ............................................................................................................. 2

3.2. Carta Aliran Latihan ................................................................................................. 4

3.3. Carta Perbandingan ................................................................................................ 8

3.4. Jadual Pembahagian Jam Kredit ............................................................................. 6

3.5. Jadual Pengalaman Pembelajaran ........................................................................ 15

A18-01-01 Engineering Drawing ............................................................................ 16

A18-01-02 Workshop Practice ............................................................................... 17

A18-01-03 Rigging and Slinging ............................................................................. 20

A18-01-04 Piping Equipment Isolation ................................................................... 22

A18-01-05 Static Equipment Maintenance ............................................................. 24

A18-01-06 Mechanical Transmission Maintenance…………………………………..26

A18-01-07 Rotating Equipment Maintenance ......................................................... 28

3.6. Silibus Profil........................................................................................................... 31

A18-01-01 Engineering Drawing ............................................................................ 32

A18-01-02 Workshop Practice ............................................................................... 36

A18-01-03 Rigging and Slinging ............................................................................. 44

A18-01-04 Piping Equipment Isolation ................................................................... 49

A18-01-05 Static Equipment Maintenance ............................................................. 57

A18-01-06 Mechanical Transmission Maintenance……… ………………………...62

A18-01-07 Rotating Equipment Maintenance ......................................................... 66

SENARAI SINGKATAN

L Lecture

D Demo

P Practice

PT Practical Test

PR Project

A Assignment

OT Oral Test

WT Written Test

O Others

IS Information Sheet

AS Assignment Sheet

WS Work Sheet

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PENDAHULUAN

1.1. Pengenalan

Sukatan latihan ini merupakan dokumen yang menggariskan perkara-perkara yang

perlu diperolehi oleh seseorang pelajar di dalam bidang kemahiran Teknologi Minyak

dan Gas (Mechanical Plant - Downstream). Semua modul yang terkandung di dalam

sukatan latihan ini akan dinilai berasaskan keterampilan bagi memastikan setiap

pelajar berkebolehan dan berkeupayaan melaksanakan modul-modul berkenaan

mengikut tahap kemahiran yang dipelajari.

Sukatan latihan ini dibangunkan mengikut format sukatan Institusi Latihan Jabatan

Tenaga Manusia (ILJTM) dan telah mengambil kira Standard Kemahiran Pekerjaan

Kebangsaan (National Occupational Skills Standard – NOSS) yang dibuat oleh

Jabatan Pembangunan Kemahiran (JPK). Sukatan latihan ini juga mengambil kira

penambahan semua duti dan tugasan selaras dengan keperluan teknologi semasa

dan memenuhi standard persijilan.

1.2. Objektif

Objektif sukatan latihan ini dibangunkan adalah untuk membantu pensyarah dalam

menyediakan pembelajaran latihan kemahiran agar keseragaman latihan dapat

dilakukan di semua ILJTM bagi Teknologi Minyak dan Gas (Mechanical Plant -

Downstream).

1.3. Pra-syarat

Kursus Teknologi Minyak dan Gas (Mechanical Plant - Downstream) merupakan

kursus peringkat Sijil Teknologi yang dikendalikan oleh Jabatan Tenaga Manusia

(JTM). Syarat kelayakan bagi kursus ini ialah calon mesti warganegara Malaysia

berumur di antara 17 hingga 30 tahun dan mempunyai kelulusan akademik berikut :

1.3.1. Kemasukan ke Semester 1

Syarat kemasukan:

1. Lepasan Sijil Pelajaran Malaysia (SPM)

a) Mempunyai SPM dengan kepujian dalam 3 subjek berikut :

i. Bahasa Melayu

ii. Sains / Fizik / Kimia

iii. Matematik / MatematikTambahan

ii

b) Lulus Bahasa Inggeris

c) Lulus dalam sesi temuduga yang dijalankan

2. Lepasan Sijil Kemahiran Malaysia (SKM)

a) Mempunyai SKM Tahap 2 dalam salah satu bidang berikut :

i. Mekanik Industri

ii. Pengeluaran / Pembuatan

iii. Kimpalan (Gas &Arka)

iv. Kimpalan (Minyak & Gas)

v. Fabrikasi Logam

vi. Pemesinan Am

b) Lulus dalam sesi temuduga yang dijalankan.

1.4. Tempoh Latihan

1.4.1. Kemasukan ke Semester 1

Tempoh latihan sepenuh masa bagi kursus ini ialah 2 tahun 3 bulan.

Pelajar diwajibkan menjalani latihan kemahiran selama dua tahun (dari

semester 1 hingga semester 4) dan pada semester 4, pelajar perlu

menjalani latihan industri (industrial training) selama tiga bulan.

1.5. Kaedah Latihan

Kaedah latihan di ILJTM bagi peringkat sijil adalah berteraskan kemahiran di mana

70% ialah latihan amali dan 30% pengajaran teori.

1.5.1. Struktur Silibus

Silibus yang digunapakai bagi kursus Sijil Teknologi Minyak dan Gas

(Mechanical Plant - Downstream) adalah seperti berikut:

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Jadual 0.1 : Struktur Silibus Kursus Teknologi Minyak dan Gas

(Mechanical Plant - Downstream)

Semester Silibus ILJTM Rujukan NOSS

1 A18 Teknologi Minyak Dan Gas


OG-015-1 Mechanical Plant

Maintenance

2

A18 Teknologi Minyak Dan Gas



Maintenance

3 A18 Teknologi Minyak Dan Gas



Maintenance

4 Latihan Industri Tiada

1.5.2. Struktur Rujukan NOSS

Jadual 0.2 : Struktur NOSS yang dirujuk dari sub sektor:

Mechanical Plant Maintenance untuk Tahap 3

TAHAP Teknologi Minyak dan Gas

(Mechanical Plant – Downstream)

5 Tiada NOSS

4 Tiada NOSS

3 OG-015-3

2 OG-015-2

1 OG-015-1

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1.6. Peluang Kerjaya

Pelajar lepasan sijil teknologi bagi kursus ini mempunyai peluang kerjaya sebagai

Juruteknik Rendah Loji Mekanikal atau pekerjaan lain yang berkaitan.

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2. SENARAI AHLI JAWATANKUASA PEMBANGUNAN SILIBUS

Panel Pembangun Silibus

1. Mohd Eley Bin Rosli

(Ketua Penyelaras)

ADTEC Batu Pahat

2. Siti Nur Insyirah Pamela Binti Abdullah

(Penolong Ketua Penyelaras)

ILP Selandar

3. Asziman Bin Sukran ADTEC Batu Pahat

4. Sahrulnizam Bin Abd Khalid ADTEC Batu Pahat

5. Mohd Suhaimi Bin Mat Din ADTEC Bintulu

6. Mohairi Bin Ahmad ILP Pasir Gudang

7. Mohd Samsudin Bin Wagiman ILP Pasir Gudang

8. Norlydiawati Binti Mohd Mustajab ILP Pasir Gudang

9. Saiful Rizal Bin Abdul Jabar ILP Labuan

10. Mohd Faizal Bin Abdul Muhaini ILP Labuan

Panel Industri

1. Saeman Bin Maat Petronas Carigali Sdn. Bhd.

2. Abd Rahman Bin Yusoff Institut Teknologi Petroleum Petronas

(INSTEP)

Urusetia/Fasilitator:

1. Che Puteh Binti Zakaria BKT, Ibu Pejabat

2. Oze Farameela Binti Otoh BKT, Ibu Pejabat

3. Hamed Bin Yacob BKT, Ibu Pejabat

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2.1. Carta Profil

SECTOR OIL & GAS

SUB SECTOR ENGINEERING

JOB AREA MECHANICAL PLANT MAINTENANCE

JOB LEVEL THREE (3) JOB AREA CODE OGM-D15-3

CORE

MECHANICAL TRANSMISSION

OVERHAUL

PUMP OVERHAUL

ROTATING EQUIPMENT OVERHAUL

OG-015-3:2012-C01

OG-015-3:2012-C02

OG-015-3:2012-C03

ELECTIVE

ROTATING EQUIPMENT

CONDITION BASE MONITORING

INSTRUMENT INSTALLATION AND

MAINTENANCE

OG-015-2:2012-E01

OG-015-3:2012-E01

COMPETENCY COMPETENCY UNIT

3

2.2. Carta Aliran Latihan

A18 SIJIL TEKNOLOGI MINYAK DAN GAS (MECHANICAL PLANT-DOWNSTREAM) -

SEMESTER 3

START

A18-03-01

MECHANICAL

TRANSMISSION

OVERHAUL

01.01 1/3

Perform gearbox

overhaul

01.02 2/3

Perform alignment

of compressor

Perform alignment

of steam / gas

turbine

01.03 3/3

PUMP OVERHAUL

A18-03-02 Service and testing

of mechanical seal

02.02 2/3

Assembly multi-

stage centrifugal

pump

02.01 1/3

Perform trouble

shooting on pump

02.03 3/3

A

COMPRESSOR

OVERHAUL

A18-03-03

Perform positive-

displacement

compressor

overhaul

03.01 1/2

Perform centrifugal

compressor

overhaul

03.02 2/2

Perform steam / gas

turbine overhaul

03.03 1/2 INTERNAL

COMBUSTION

OVERHAUL

A18-03-04 Perform internal

combustion engine

overhaul

03.04 2/2

4

Service manual

slinging equipment

01.01

1/3

Perform rigging and

manual lifting

activities

01.02

2/3

Perform rigging and

lifting using

overhead crane

01.03

3/3

BERSAMBUNG

DI SEMESTER 4

A

ROTATING

EQUIPMENT

CONDITION BASE

MONITORING

A18-03-05

Perform vibration

measurement of

the rotating

equipment

06.01 1/2

Perform

temperature

measurement of

the rotating

equipment body

and bearings

06.02 2/2

Perform

communication

check

07.01 1/3 INSTRUMENT

FUNCTIONALITY

TEST

A18-03-06 Perform functional

test of unit

shutdown system

07.02 2/3

Perform loop test

07.03 3/3

5

2.3. Carta Perbandingan


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CU TITLE CU WORK ACTIVITIES

WA

N

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BER

A1

8-0

3-0

1

A1

8-0

3-0

2

A1

8-0

3-0

3

A1

8-0

3-0

4

A1

8-0

3-0

5

A1

8-0

3-0

6

1

MECHANICAL TRANSMISSION

OVERHAUL

Perform gear box overhaul 01.01

Perform alignment of compressor 01.02

Perform alignment of steam/ gas turbine 01.03

2 PUMP OVERHAUL

Assembly multi-stage centrifugal pump 02.01

Service and testing of mechanical seal 02.02

Perform trouble shooting on pump 02.03

3

ROTATING

EQUIPMENT

OVERHAUL

Perform positive-displacement compressor overhaul 03.01

Perform centrifugal compressor overhaul 03.02

Perform steam/ gas turbine overhaul. 03.03

Perform internal combustion engine overhaul 03.04

1

ROTATING

EQUIPMENT

CONDITION BASE

MONITORING

Perform vibration measurement of rotating equipment

06.01

Perform temperature measurement of the rotating equipment body and bearings

06.02

1

INSTRUMENT

INSTALLATION

AND

MAINTENANCE

Perform communication check 07.01

Perform Functional Test of Unit Shutdown System (USD)

07.02

Perform loop test 07.02

NOSS (New Format)

JTM SYLLABUS

6

2.4. Jadual Pembahagian Jam Kredit

A18 SIJIL TEKNOLOGI MINYAK DAN GAS (MECHANICAL PLANT-DOWNSTREAM) – SEMESTER 3

KOD MODUL TAJUK MODUL

TASK JAM KREDIT

A/(PEMBERAT (1.5) X 20 )

TEORI (JAM)

AMALI (JAM)

JAM KREDIT TEORI

JAM KREDIT AMALI

JUMLAH JAM

KREDIT

KREDIT MODUL

A18-03-01 Mechanical Transmission Overhaul 36.0 84.0 1.2 2.8 4.0 4

A18-03-02 Pump Overhaul 36.0 84.0 1.2 2.8 4.0 4

A18-03-03 Compressor Overhaul 36.0 84.0 1.2 2.8 4.0 4

A18-03-04 Internal Combustion Overhaul 36.0 84.0 1.2 2.8 4.0 4

A18-03-05 Rotating Equipment Condition Base Monitoring

9.0 21.0 0.3 0.7 1.0 1

A18-03-06 Instrument Installation and Maintenance

9.0 21.0 0.3 0.7 1.0 1

JUMLAH LATIHAN ( SUBJEK TERAS ) 162.0 378.0 5.4 12.6 18.0 18

PERATUS LATIHAN ( SIJIL ) 30% 70%

PI-3111 / PM-3111 Pendidikan Islam 3 / Pengetahuan Moral 3

30 - 1.0 - 1.0 1

JUMLAH LATIHAN ( SUBJEK UMUM ) 30.0 - 1.0 - 1.0 1

JUMLAH KESELURUHAN LATIHAN 570.0 19

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JADUAL PENGALAMAN PEMBELAJARAN

A18-03-01 : MECHANICAL TRANSMISSION OVERHAUL Terminal Performance Objective:

Carry Out Mechanical Transmission Overhaul using equipment safety manual, gear box, centrifugal pump fitted with single mechanical seal for water service, magnetic or sealers pump, water tank, piping system, assembly drawing and working table so that gear box overhaul, alignment of compressor, steam and gas turbine performed in accordance with company standard for maintenance job.

PENGALAMAN PEMBELAJARAN (LEARNING EXPERIENCE)

OBJEKTIF MEMBOLEH (ENABLING OBJECTIVE)

LE 1 : PERFORM GEAR BOX OVERHAUL

Perform gear box overhaul using equipment safety manual, gear box, water tank, piping system, assembly drawing and working table so that Job Safety Analysis (JSA) prepared, Permit to Work (PTW) raised, gear box assembly dismantled and inspected, precision measurements and clearances verified, gear box assembled and tested in accordance with company standard for maintenance job.

LE 2 : PERFORM ALIGNMENT OF COMPRESSOR

Perform alignment of compressor using equipment safety manual, centrifugal pump fitted with single mechanical seal for water service, magnetic or sealers pump, water tank, piping system, assembly drawing and working table so that work procedures, checklist, manual and recording sheet identified, compressor assembly drawing determined, isolation/de isolation executed, alignment works and test run of the compressor completed and servicing record prepared in accordance with company standard for maintenance job.

9

LE3 : PERFORM ALIGNMENT OF STEAM / GAS TURBINE

Perform alignment of steam / gas turbines using equipment safety manual, water tank, piping system, assembly drawing and working table so that Job Safety Analysis (JSA) prepared, Permit to Work (PTW) raised, cause of failure identified, Steam/gas turbine alignment carried out , de-isolation completed and maintenance report updated in accordance with company standard for maintenance job.

10


A18-03-02 : PUMP OVERHAUL Terminal Performance Objective:

Carry out Pump Overhaul using equipment safety manual, centrifugal pump fitted with single mechanical seal for water service, magnetic or sealers pump, water tank, piping system, assembly drawing and working table so that multi-stage centrifugal pump assembled, mechanical seal serviced, tested and troubleshooting on pump performed in accordance with company standard for maintenance job.



LE 1 : ASSEMBLY MULTI-STAGE CENTRIFUGAL PUMP

Assembly multi-stage centrifugal pump using equipment safety manual, centrifugal pump fitted with single mechanical seal for water service, magnetic or sealers pump, water tank, piping system, assembly drawing and working table so that correct sealing mechanism and equipment de-isolation procedure obtained, overhaul activities prepared, pump seal installed, free rotation of components performed, multistage centrifugal assembled and technical record prepared in accordance with company standard for maintenance job.

LE 2 : SERVICE AND TESTING OF MECHANICAL SEAL

Service and testing of mechanical seal using equipment safety manual, centrifugal pump fitted with single mechanical seal for water service, magnetic or sealers pump, water tank, piping system, assembly drawing and working table so that correct sealing materials selected, mechanical seal dismantled, internal component cleaned and serviced, mechanical seal assembled, inspected and tested in accordance with company standard for maintenance job.

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LE 3 : PERFORM TROUBLESHOOTING ON PUMP

Perform troubleshooting on pump using equipment safety manual, centrifugal pump fitted with single mechanical seal for water service, magnetic or sealers pump, water tank, piping system, assembly drawing and working table so that P&ID interpreted, pump components and construction assembly drawing determined, measurement technique are checked and defined, cause of failure identified and rectified, problem component fixed and troubleshooting report produced in accordance with company standard for maintenance job.

12


A18-03-03 : COMPRESSOR OVERHAUL Terminal Performance Objective:

Carry out Compressor Overhaul using equipment safety manual, compressor components, centrifugal compressor, water tank, piping system, assembly drawing and working table so that positive-displacement compressor and centrifugal compressor overhaul performed in accordance with company standard for maintenance job.



LE 1 : PERFORM POSITIVE-DISPLACEMENT COMPRESSOR OVERHAUL

Perform positive-displacement compressor overhaul using equipment safety manual, compressor components, centrifugal compressor, water tank, piping system, assembly drawing and working table so that positive-displacement compressor components and construction dismantled, assembly drawing defined, defective component replaced or rectified pre-commissioning checks performed and commissioning functionality test carried out in accordance with company standard for maintenance job.

LE 2 : PERFORM CENTRIFUGAL COMPRESSOR OVERHAUL

Perform centrifugal compressor overhaul using equipment safety manual, compressor components, centrifugal compressor, water tank, piping system, assembly drawing and working table so that checklist / maintenance manual identified, centrifugal compressor components and construction dismantled, assembly drawing defined, defective component replaced or rectified and commissioning functionality test carried out in accordance with company standard for maintenance job.

13


A18-03-04 : INTERNAL COMBUSTION OVERHAUL Terminal Performance Objective:

Carry out Compressor Overhaul using equipment safety manual, compressor components, centrifugal compressor, steam / gas turbines, labyrinth seal packing, internal combustion engines, water tank, piping system, assembly drawing and working table so that steam / gas turbine and internal combustion engine overhaul performed in accordance with company standard for maintenance job.



LE 1 : PERFORM STEAM / GAS TURBINE OVERHAUL

Perform steam / gas turbine overhaul using equipment safety manual, compressor components, centrifugal compressor, steam / gas turbines, labyrinth seal packing, water tank, piping system, assembly drawing and working table so that

LE 2 : PERFORM INTERNAL COMBUSTION ENGINE OVERHAUL

Perform internal combustion engine overhaul using equipment safety manual, compressor components, centrifugal compressor, labyrinth seal packing, internal combustion engines, water tank, piping system, assembly drawing and working table so that

14


A18-03-05 : ROTATING EQUIPMENT CONDITION BASE MONITORING Terminal Performance Objective:



LE 1 :

LE 2 :

15


A18-03-06 : INSTRUMENT FUNCTIONALITY TEST Terminal Performance Objective:



LE 1 :

LE 2 :

16

LE 3 :

32

SYLLABUS PROFILE

Course Code : Course : Semester : NOSS Code :

A18 TEKNOLOGI MINYAK & GAS ( MECHANICAL PLANT – DOWNSTREAM ) 1 OG – 015 – 1

Knowledge Credit Hours : 0.6 Practical Credit Hours : 1.4 Total Credit Hours : 2.0

Terminal Performance Objective (TPO) Construct Engineering Drawing using plant layout, safety handbook, drawing equipment and computer so that general, piping and instrument part created in accordance with company standard and mechanical engineering (oil and gas) drafting procedure.

Module : A18-01-01 : ENGINEERING DRAWING

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CoCU / Work Activities No. : OG-015-1:2012-C09 / 09.01, 09.02, 09.03

Learning Experience (LE)

Knowledge Hrs Practical Hrs

LE 1 : PREPARE PART ENGINEERING DRAWING

1.1 Identify basic principle of Pipe Drawings 1.1.1 Engineering Drawing. 1.1.2 Equipment /Machine Parts 1.1.3 Equipment / Machine Part drawing.

Creating Basic Drawing using CAD software

Manipulating Objects

Altering Objects

Annotation Drawing

Hatching

4.5

L WT IS AS

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Dimensioning

Layer Management 1.1.4 Part drawing technique.

1.2 Draw using CAD software 1.2.1 Interpret Engineering Drawing. 1.2.2 Identify Parts 1.2.3 Produce Part drawing. 1.2.4 Comply Part drawing

10.5 P PT WS

LE 2 : CREATE PIPING AND INSTRUMENT DIAGRAM ( P& ID ) DRAWING

2.1 Identify pipe and instrument diagram 2.1.1 Piping and Instrument Drawing (P&ID)

Flow diagram usage

Piping Arrangement

Piping symbol 2.1.2 Part drawing Technique

Flow plan arrangement

Flow diagram instrument

Pipe and instrument diagram drawing creating techniques

13.5

L WT IS AS

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CoCu / Task No. : OG-015-1:2012-C09 / 09.01



2.1.3 Part in piping system.

Type and material for gasket

Type of valves and instruments 2.1.4 Piping Part drawing

Isometric Projection

2.1.5 Interpret Piping and Instrument Drawing (P&ID) 2.1.6 Identify Piping Parts. 2.1.7 Produce Piping Part drawing 2.1.8 Identify Type and material for gasket. 2.1.9 Identify type of valves and instruments. 2.1.10 Comply Piping Part drawing.

31.5

P

PT

WS

Total Hours 18 42

35

Tools/ Equipment/ Materials : Computer, Drawing Software, Drawing Tools, Plant Layout and Safety Handbook

Reference Books (Title, Atr, Publisher) :

1. Roy A. Parisher, Robert A. Rhea (2000), Pipe Drafting and Design (2nd Edition), Gulf Professional Publishing, ISBN 13: 978-0-7506-7439

2. Richard J. Beale, Paul Bowers, Peter Smith (2010), Plant Layout And Construction Design, Gulf Publishing Company, ISBN-10: 1933762373, ISBN-13: 978-193376237

3. Pennock, James O. Piping Engineering Leadership for Process Plant Projects, Gulf Professional Publishing, ISBN: 0-88415-347-9

4. William E. Forsthoffer, Forsthoffer’s Best Practice Handbook for Rotating Machinery, Elsevier Ltd, ISBN: 978-0-08-096676-2

5. Heinz P. Bloch, Fred K. Geitner,1993, Practical Machinery Management for Process Plants Volume 4 – Major Process Equipment Maintenance and Repair, Gulf Professional Publishing, ISBN: 0-88415-663-X

6. Arthur Townsend 1980, Maintenance of Process Plant: A Guide to Safe Practice, Institution of Chemical Engineers, ISBN: 0-85295-292-9

Manuals :

36

SYLLABUS PROFILE




Terminal Performance Objective (TPO)

Carry out Workshop Practise using precision measuring equipment, gasket sheet, gasket cutter, hole punch, sniper, fittings equipment, oxy-acetylene, gas cutting set, drilling machine, tap and dies set, broken bolts extractor and related drawings so that work piece measurement performed, gasket, cold and hot cutting performed, key fitting of hub / shaft installation performed, equipment components drilled and broken stud bolts extracted in accordance with company standard for maintenance job.

Module : A18-01-02 : WORKSHOP PRACTISE

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CoCU / Work Activities No. : OG-015-1:2012-C01 / 01.01, 01.02, 01.03, 01.04, 01.05, 01.06, 01.07



LE 1 : PERFORM WORK PIECE MEASUREMENT

1.1.1 Metric and Imperial Units. 1.1.2 Type of the measuring tools:

Straight Edge

Spirit Level

Steel Rule

Feeler Gauge

Vanier Calliper

4.5

L WT IS AS

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Outside Micrometer

Dial Gauge

Bore gauge

Depth gauge 1.1.3 Measuring techniques

L WT IS AS

1.2.1 Use of the measuring tools 1.2.2 Apply metric and imperial units. 1.2.3 Apply measuring technique 1.2.4 Measure Inside diameter, depth of grooves and length of a work piece. 1.2.5 Measure shaft outside diameter and shaft run 1.2.6 Verify surface flatness

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LE 2 : PERFORM GASKET CUTTING

2.1.1 Tools usage and selection 2.1.2 Measurement techniques 2.1.3 Marking techniques

steel ruler/tape

divider

compass 2.1.4 Gasket cutting techniques/methods 2.1.5 Gasket usage and selection

3

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2.2.1 Prepare tools, equipment and materials. 2.2.2 Apply measurement and marking technique. 2.2.3 Mark gasket sheet and cut. 2.2.4 Perform measurement/ sketch. 2.2.5 Use Gasket cutter, hole punch and sniper.

6

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LE 3 : PERFORM COLD CUTTING

3.1.1 Materials usage and selection 3.1.2 Tools usage and selection 3.1.3 Technical drawing/sketch 3.1.4 Measurement work piece to cut technique. 3.1.5 Coolant selection 3.1.6 Cutting techniques

3

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3.2.1 Prepare tools, equipment and materials. 3.2.2 Mark and secure work piece prior cutting. 3.2.3 Cut work piece to size. 3.2.4 Select correct tools/equipment and materials 3.2.5 Read and interpret technical drawing/sketch 3.2.6 Use vice, clamps and measurement tools 3.2.7 Perform layout/mark out 3.2.8 Do measurement/sketch

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LE 4 : PERFORM HOT CUTTING

4.1.1 Materials usage and selection 4.1.2 Tools/equipment usage and selection 4.1.3 Cutting technologies guidelines. 4.1.4 Technical drawing/sketch 4.1.5 Measurement work piece to cut 4.1.6 Cutting techniques

1.5

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4.2.1 Prepare tools, equipment and materials. 4.2.2 Select correct tools/equipment and materials 4.2.3 Read and interpret technical drawing/sketch 4.2.4 Perform layout/mark out 4.2.5 Do measurement/sketch 4.2.6 Mark and secure work piece prior cutting. 4.2.7 Cut work piece to size. 4.2.8 Use vice, clamps and measurement tools

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LE 5 : PERFORM KEY FITTING TO HUB/ SHAFT INSTALLATION

5.1.1 Measurement techniques 5.1.2 Measuring tools 5.1.3 Cold cutting techniques 5.1.4 Material selection 5.1.5 File selection 5.1.6 Filing techniques

1.5

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5.2.1 Dimensions for key way measure. 5.2.2 Material for key selected and cut to size. 5.2.3 Perform Final key fitting 5.2.4 Use measuring tools 5.2.5 Mark key material 5.2.6 Carry out cold cutting 5.2.7 Select material for the key 5.2.8 Perform file key to accurate size and tolerances 5.2.9 Perform fit key to key way

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LE 6 : DRILL EQUIPMENT COMPONENTS

6.1.1 Component material 6.1.2 Marking techniques 6.1.3 Measurement techniques 6.1.4 Describe drill bite.

3

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6.2.1 Mark location of drill point on component 6.2.2 Setting up component on drill machine. 6.2.3 Drill the work piece. 6.2.4 Inspection part after drill.

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LE 7 : EXTRACT BROKEN STUDS

7.1.1 Type of stud. 7.1.2 Stud material. 7.1.3 Damage locates guidelines.

1.5

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7.2.1 Prepare flatness of broken stud surface 7.2.2 Extract and drill broken stud. 7.2.3 Clean internal thread

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Total Hours 18 42

43



1. Glenn M. Tillman, Basic Mechanical Maintenance Procedures at Water and Wastewater Plants, Taylor & Francis, 1991, ISBN: 0-87371-429-6, 9-7808737-1429-7





6. Anthony Kelly 2006, Strategic Maintenance Planning, Elsevier Ltd, ISBN 13: 978-0-75-066992-4 7. Keith Escoe, Pressure Vessel and Stack – Field Repair Manual, Butterworth-Heinemann 2008,

ISBN: 978-0-7506-8766-9 8. Maurice Stewart, Oran T. Lewis, Heat Exchanger Equipment Field Manual: Common Operating

Problem and Practical Solution, Gulf Professional Publishing, ISBN: 978-0-12-397016-9 9. Tony Wild 2002, Best Practice in Inventory Management, Butterworth-Heinemann, ISBN: 0-7506-

5458-9 10. Micheal Speegle, Safety, Health and Environmental Concepts for the Process Industry 2nd Edition,

Delmar Cengage Learning, ISBN-13: 978-1-133-01347-1 11. Michael D. Holloway, Chikezie Nwaoha & Oliver A. Onyewuenyi, Process Plant Equipment –

Operation, Control and Reliability, John Wiley & Sons, ISBN: 978-1-118-02264-1 12. Micheal E. Brumbach and Jeffrey A. Clade, Industrial Maintenance, Thomson Delmer Learning,

ISBN: 0-7668-2695-3

Manuals :

44

SYLLABUS PROFILE




Terminal Performance Objective:

Perform Rigging and Slinging using overhead crane, safety handbook, manual operation, grease, lifting and rigging tools, spares and materials so that manual slinging equipment serviced and rigging activities performed using overhead crane and manually in accordance with rigging and lifting procedure.

Module : A18-01-03 : RIGGING AND SLINGING

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LE 1 : PERFORM MANUAL LIFTING EQUIPMENT SERVICE

1.1.1 Common/special tools, spares and materials. 1.1.2 Guidelines/ steps/ work of Manual Lifting Equipment manual instructions :-

Checklist / maintenance manual

Cause and defects/ faults of component parts guidelines

Lubrication method

Testing and acceptance criteria notes 1.1.3 Service interval guidelines

3

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1.2.1 Select appropriate tools, spares and materials. 1.2.2 Identify lifting equipment for service and testing Purposes. 1.2.3 Dismantle and assemble the lifting equipment. 1.2.4 Perform Load Test and Functional check of the lifting equipment. 1.2.5 Write a technical report 1.2.6 Execute preventive maintenance.

7

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LE 2 : PERFORM RIGGING AND MANUAL LIFTING ACTIVITIES

2.1.1 Common/special tool spares and materials 2.1.2 Weight and size of the load calculation method. 2.1.3 Type of rigging and lifting equipment guidelines:-

Safe working load (SWL) calculation method

Load to be lifted based on centre of gravity calculation

2.1.4 Rigging and Lifting procedures/guideline 2.1.5 Rigging and Lifting techniques

3

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2.2.1 Select appropriate lifting and rigging tools,

spares and materials 2.2.2 Identify weight and size of load. 2.2.3 Inspect physically and visually on rigging and

lifting equipment 2.2.4 Interpret rigging and lifting activities procedure 2.2.5 Ensure load and rigging equipment are secured

7

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LE 3 : PERFORM RIGGING AND LIFTING USING OVERHEAD CRANE

3.1.1 Common/special lifting tools, spares and

materials. 3.1.2 Weight and size of load calculation method. 3.1.3 Type of rigging and lifting equipment

(overhead type) for the specified job. 3.1.4 Safe working load (SWL) calculation method. 3.1.5 Load to be lifted based on Centre of Gravity

calculation 3.1.6 Rigging and Lifting procedures/guideline 3.1.7 Rigging and Lifting techniques

3

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3.2.1 Select appropriate lifting and rigging tools, spares and materials. 3.2.2 Determine weight and size of load with Overhead Crane. 3.2.3 Inspect physically and visually on rigging and lifting equipment 3.2.4 Comply to rigging and lifting activities procedure 3.2.5 Verify load and rigging equipment are secured.

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Total Hours 9 21

48

Tools/ Equipment/ Materials :

Plant Layout/Workplace/Shop Floor, Safety Handbook, Equipment Safety Manual, Emergency and Hazardous Signage, Standard Operating Procedure, Manual Operation, Job order, assembly drawing, specification sheet, Working table, Chain block with webbing slings, shackle, wire rope, Lifting accessories and grease.













ISBN: 0-7668-2695-3

Manuals :

49

SYLLABUS PROFILE





Carry out Piping System and Equipment Isolation using safety handbook, manual operation, appropriate equipment, grease and checklist so that preventive maintenance on valves, strainers cleaning, re-gasketing, spading, valves replacement, positive isolation and blinding activities performed in accordance with company standard for maintenance job and manuals.

Module : A18-01-04 : PIPING EQUIPMENT ISOLATION

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CoCU / Work Activities No. : OG-015-1:2012-C02 /C04 / 02.01, 02.02, 02.03, 02.04, 04.01, 04.02, 04.03, 04.04



LE 1 : PERFORM PREVENTIVE MAINTENANCE ON VALVES

1.1.1 Preventive Maintenance (PM) schedule 1.1.2 Valves type, function and component :-

Technical drawing/sketch

Valve operation.

Valve parts.

Tightening procedure/method

Blast and paint valve technique.

Valve construction and parts.

6

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1.1.3 Cleaning method technique.

Dirt, sludge, rust guidelines. 1.1.4 Sealing mechanism.

Type of sealing material 1.1.5 Valve lubrication method

Types of grease.

Identify packing and greasing points 1.1.6 Check list.

L WT IS AS

1.2.1 Check valve external condition 1.2.2 Clean valve external components 1.2.3 Perform visual inspection 1.2.4 Select cleaning agent 1.2.5 Identify packing position 1.2.6 Prepare check list/report 1.2.7 Update maintenance checklist

15

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LE 2 : PERFORM STRAINERS CLEANING AND REPAIR

2.1.1 Type of strainer 2.1.2 Material of construction 2.1.3 Strainer assembly and dismantle method. 2.1.4 Pressure Rating and size 2.1.5 Product Manual

6

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2.2.1 Prepare tools, equipment and materials 2.2.2 Dismantle Strainer 2.2.3 Clean strainer. 2.2.4 Perform Repair works on strainer. 2.2.5 Assemble strainer

9

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LE 3 : PERFORM RE-GASKETING, SPADING / DE-SPADING

3.1.1 Types Of Gasket 3.1.2 Gasket Materials 3.1.3 Area of application 3.1.4 Types Of Sealant 3.1.5 Pipe flange blind method.

4.5

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3.2.1 Prepare tools, equipment and materials. 3.2.2 Carry out blinding 3.2.3 Insert gasket pipe flanges. 3.2.4 Making and install gasket. 3.2.5 Remove pipes flange blind

12

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LE 4 : PERFORM VALVES REPLACEMENT

4.1.1 Pressure reliving devices external condition. 4.1.2 Pressure reliving devices external components. 4.1.3 Re-painting pressure reliving device guidelines. 4.1.4 Maintenance procedure.

4.5

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4.2.1 Check pressure reliving devices external

condition. 4.2.2 Clean Pressure reliving devices external

components. 4.2.3 Re-painting pressure reliving devices. 4.2.4 Update Maintenance checklist.

12

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LE 5 : PERFORM POSITIVE ISOLATION AND BLINDING ACTIVITIES

5.1.1 Materials usage and selection 5.1.2 Tools/equipment usage and selection 5.1.3 Equipment and PI&D drawing 5.1.4 Process parameters 5.1.5 Blinding and spading list 5.1.6 Equipment isolation and de-isolation procedure.

6

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5.1.7 Blinding procedure. 5.1.8 Break flange procedure. 5.1.9 Drum and separator product. 5.1.10Joint Isolation /blinding of flange procedure. 5.1.11Re install joints after completion of all work procedure. 5.1.12Pressure Vessel product. 5.1.13Ventilation function and procedures 5.1.14Line colour coding 5.1.15Type of tower and column 5.1.16Structure of tower and column 5.1.17Construction of tower and column 5.1.18 Internal hazard in tower and column. 5.1.20Type of transmission 5.1.21Type of Lubricant 5.1.22Transmission Part and components 5.1.23 Isolation/ blinding of flange joints procedure. 5.1.24Heat exchanger 5.1.25Transmission drawing

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5.2.1 Prepare tools, equipment and materials. 5.2.2 Carry out isolation/blinding of flange joints. 5.2.3 Read and interpret equipment and PI&D drawing. 5.2.4 Install blind / spade and correct gasket. 5.2.5 Perform Drum and separator product. 5.2.6 Accesses work area.. 5.2.7 Joint Isolation /blinding of flange. 5.2.8 Open Manhole and vent cover. 5.2.9 Perform Ventilate vessel 5.2.10Assess work area to equipment plot/ plant layout. 5.2.11Ventilate column and tower. 5.2.12Carry out Heat exchanger is ventilated. Carry out Joints are re-instated after completion of all work.

15

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Total Hours 27 63

56


Plant layout/workplace/shop floor, Safety handbook, Equipment safety manual, emergency and hazardous signage, Standard operating procedure , Manual operation, Job order, assembly drawing and specification sheet, Working table, Chain block with webbing slings, shackle, wire rope, Lifting accessories, grease, Job order, assembly drawing and specification sheet, Small size centrifugal pump fitted with single mechanical seal for water service, Small size magnetic or sealers pump, Water tank and piping system .













ISBN: 0-7668-2695-3

Manuals :

57

SYLLABUS PROFILE





Carry out Static Equipment Maintenance using plant layout, safety handbook, equipment safety manual, emergency and hazardous signage, standard operating procedure, chain block with webbing slings, shackle, wire rope, lifting accessories, grease, drum (pressure vessel), column, shell and tube heat exchanger and storage tank so that preventive maintenance for pressure vessel, column, heat exchanger and storage tank performed in accordance with company standard for maintenance job.

Module : A18-01-05 : STATIC EQUIPMENT MAINTENANCE

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CoCU / Work Activities No. : OG-015-1:2012-C08 / 08.01, 08.02, 08.03, 08.04



LE 1 : PERFORM PREVENTIVE MAINTENANCE FOR PRESSURE VESSEL

1.1.1 Permit to Work 1.1.2 Lubrication schedule. 1.1.3 Lubricants types and quantity. 1.1.4 Tools required. 1.1.5 Lubrication level setting guidelines. 1.1.6 Pressure vessel function and construction. 1.1.7 Types of maintenance. 1.1.8 Maintenance document record.

7.5

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1.2.1 Select and obtain lubricant, tools & consumable 1.2.2 Identify required checklist and manual. 1.2.3 Check Pressure vessel external condition. 1.2.4 Locate lubrication points 1.2.5 Clean Pressure vessel external components. 1.2.6 Check and confirm pressure vessel grounding. 1.2.7 Update Maintenance checklist

16.5

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LE 2 : PERFORM PREVENTIVE MAINTENANCE FOR COLUMN

2.1.1 Permit to Work 2.1.2 Lubrication schedule. 2.1.3 Lubricants types and quantity. 2.1.4 Tools required. 2.1.5 Preventive maintenance checklist. 2.1.6 Lubrication level setting. 2.1.7 Lubrication points. 2.1.8 Column function and construction. 2.1.9 Column operating parameters (temperature, noise) 2.1.10Types of maintenance. 2.1.11Maintenance document record.

6

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2.2.1 Select and obtain lubricant, tools & consumable 2.2.2 Prepare Permit to work 2.2.3 Identify required checklist and manual. 2.2.4 Check column external condition. 2.2.5 Locate lubrication points 2.2.6 Use lubrication equipment 2.2.7 Clean column external components. 2.2.8 Check and confirm column grounding. 2.2.9 Update Maintenance checklist

15

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LE 3 : PERFORM PREVENTIVE MAINTENANCE FOR HEAT EXCHANGER

3.1.1 Permit to Work Lubrication schedule. 3.1.2 Lubricants types and quantity.

Lubrication level setting.

Lubrication points 3.1.3 Tools required. 3.1.4 Heat exchanger function and construction.

Heat exchanger operating parameters (temperature, noise)

3.1.5 Types of maintenance. 3.1.6 Maintenance document record.

7.5

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3.2.1 Select and obtain lubricant, tools & consumable 3.2.2 Identify required checklist and manual. 3.2.3 Check heat exchanger external condition. 3.2.4 Locate lubrication points 3.2.5 Use lubrication equipment 3.2.6 Clean heat exchanger external components. 3.2.7 Check and confirm heat exchanger grounding. 3.2.8 Update Maintenance checklist

16.5

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LE 4 : PERFORM PREVENTIVE MAINTENANCE FOR STORAGE TANK

4.1.1 Permit to Work. 4.1.2 Tools required. 4.1.3 Preventive maintenance checklist. 4.1.4 Storage tank function and construction. 4.1.5 Types of maintenance. 4.1.6 Maintenance document record.

6

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4.2.1 Select and obtain lubricant, tools & consumable 4.2.2 Identify required checklist and manual. 4.2.3 Check heat storage tank condition. 4.2.4 Clean heat storage tank components. 4.2.5 Update Maintenance checklist

15

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Total Hours 27 63

61


Plant layout/workplace/shop floor, Safety handbook, Equipment safety manual, emergency and hazardous signage, Standard operating procedure, Manual operation, Job order, assembly drawing and specification sheet, Working table, Chain block with webbing slings, shackle, wire rope, Lifting accessories, grease, Drum (pressure vessel), Column, Shell & tube heat exchanger, Storage tank, Centrifugal pump using mechanical seal, Positive displacement pump and Magnetic (seal less) pump.













ISBN: 0-7668-2695-3

Manuals :

62

SYLLABUS PROFILE





Carry out Mechanical Transmission Maintenance using plant layout, safety handbook, equipment safety manual, emergency and hazardous signage, standard operating procedure, chain block with webbing slings, shackle, wire rope, lifting accessories and grease so that transmission part lubrication, sprockets/belts/chain services/repair/replacement and preventive maintenance on transmission equipment performed in accordance with company standard for maintenance job.

Module : A18-01-06 : MECHANICAL TRANSMISSION MAINTENANCE

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LE 1 : PERFORM TRANSMISSION PART LUBRICATION

1.1.1 Permit to work 1.1.2 Lubrication schedule. 1.1.3 Lubricants types and quantity. 1.1.4 Lubrication tools / equipment. 1.1.5 Lubricants types and quantity. 1.1.6 Document record.

3

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1.2.1 Select and obtain lubricant, tools & consumable. 1.2.2 Identify greasing points and parts to be

lubricated. 1.2.3 Apply lubrication with the correct lubricant type

and quantity. 1.2.4 Record work activities

7.5

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LE 2 : PERFORM SPROCKETS/ BELTS/ CHAIN SERVICES/ REPAIR/ REPLACEMENT

2.1.1 Tools and spare part. 2.1.2 Sprocket belt and chain. 2.1.3 Remove and reinstall sprocket, pulley and belt

and chain procedure

3

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2.2.1 Prepare tools and spare part. 2.2.2 Check sprocket , belt and chain 2.2.3 Remove and reinstall sprocket, pulley, belt and

chain.

7.5

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LE 3 : PERFORM PREVENTIVE MAINTENANCE ON TRANSMISSION EQUIPMENT

3.1.1 Transmission equipment external condition. 3.1.2 Clean transmission equipment external

components procedure. 3.1.3 Maintenance checklist.

3

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3.2.1 Check transmission equipment external

condition. 3.2.2 Clean transmission equipment external

components 3.2.3 Perform update maintenance checklist.

6

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Total Hours 9 21

65


Plant layout/workplace/shop floor, Safety handbook, Equipment safety manual, emergency and hazardous signage, Standard operating procedure, Manual operation, Job order, assembly drawing and specification sheet, Working table, Chain block with webbing slings, shackle, wire rope, Lifting accessories, grease, Job order, assembly drawing and specification sheet, Small size centrifugal pump fitted with single mechanical seal for water service, Small size magnetic or sealers pump, Water tank and piping system













ISBN: 0-7668-2695-3

Manuals :

66

SYLLABUS PROFILE





Carry out Rotating Equipment Maintenance using plant layout, safety handbook, equipment safety manual, emergency and hazardous signage, standard operating procedure, chain block with webbing slings, shackle, wire rope, lifting accessories, grease, pumps, compressor, blower, fan, steam/gas turbine, internal combustion engine, petrol and diesel engine so that preventive maintenance on pumps, compressor, blower, fan, steam/gas turbine, internal combustion engine and positive displacement pumps overhaul performed in accordance with company standard for maintenance job.

Module : A18-01-07 : ROTATING EQUIPMENT MAINTENANCE

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CoCU / Work Activities No. : OG-015-1:2012-C06 / C07 / 06.01, 06.02, 07.01, 07.02, 07.03, 07.04, 07.05



LE 1 : PERFORM PREVENTIVE MAINTENANCE ON PUMPS

1.1.1 Lubrication schedule. 1.1.2 Lubricants types, quantity and method manual. 1.1.3 Tools list. 1.1.4 Preventive maintenance checklist. 1.1.5 Pump function and construction, operating

parameters (temperature, noise) 1.1.6 Maintenance document record.

6

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1.2.1 Remove and re install sprocket, pulley belt and

chain. 1.2.2 Carry out preventive maintenance work 1.2.3 Select and obtain lubricant, tools & consumable 1.2.4 Locate lubrication points 1.2.5 Use lubrication equipment 1.2.6 Fill in PM checklist form 1.2.7 Record findings

12

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LE 2 : PERFORM POSITIVE DISPLACEMENT PUMPS OVERHAUL

2.1.1 Lubrication schedule. 2.1.2 Lubricants types, quantity and method. 2.1.3 Tools required. 2.1.4 Preventive maintenance checklist. 2.1.5 Pump function and construction. 2.1.6 Pumps operating

6

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2.1.1 Prepare tools and materials 2.1.2 Dismantle and clean the pump parts. 2.1.3 Re- assembles the pump parts. 2.1.4 Run test the pump

12

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LE 3 : PERFORM PREVENTIVE MAINTENANCE ON COMPRESSOR

3.1.1 Tools, equipment and materials 3.1.2 Lubrication type and quantity 3.1.3 Preventive maintenance checklist 3.1.4 Maintenance procedures 3.1.5 Basic compressors, working principles 3.1.6 Report writing

4.5

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3.2.1 Prepare tools and materials according Work

procedure. 3.2.2 Perform Preventive Maintenance according to

instruction manual. 3.2.3 Identify Preventive maintenance checklist 3.2.4 Follow the PM checklist 3.2.5 Fill in PM checklist 3.2.6 Record findings

12

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LE 4: PERFORM PREVENTIVE MAINTENANCE ON BLOWER

4.1.1 Tools, equipment and materials 4.1.2 Lubrication type and quantity 4.1.3 Preventive maintenance checklist 4.1.4 Maintenance procedures 4.1.5 Basic blower working principles 4.1.6 Report writing

4.5

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4.2.1 Prepare tools and materials according Work procedure.

4.2.2 Perform Preventive Maintenance according to instruction manual.

4.2.3 Identify Preventive maintenance checklist 4.2.4 Follow the PM checklist 4.2.5 Fill in PM checklist 4.2.6 Record findings

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LE 5: PERFORM PREVENTIVE MAINTENANCE ON FAN

5.1.1 Tools, equipment and materials 5.1.2 Lubrication type and quantity 5.1.3 Preventive maintenance checklist 5.1.4 Maintenance procedures 5.1.5 Basic fan working principles 5.1.6 Report writing

4.5

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instruction manual. 5.2.3 Identify Preventive maintenance checklist 5.2.4 Fill in PM checklist

12

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LE 6: PERFORM PREVENTIVE MAINTENANCE ON STEAM / GAS TURBINE

6.1.1 Introduction Gas and Steam Turbine. 6.1.2 Tools and materials. 6.1.3 Preventive maintenance work. 6.1.4 Maintenance checklist.

4.5

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6.2.1 Prepare tools and materials. 6.2.2 Perform preventive maintenance work. 6.2.3 Update and complete preventive maintenance

checklist.

12

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LE 7: PERFORM PREVENTIVE MAINTENANCE ON INTERNAL COMBUSTION ENGINE

7.1.1 Tools and materials. 7.1.2 Cooling water system. 7.1.3 Combustion Engine lubrication system. 7.1.4 Servicing of air and exhaust system guidelines 7.1.5 Fuel system in Combustion Engine.

6

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7.2.1 Prepare tools and materials. 7.2.2 Inspect and service Cooling water system. 7.2.3 Carry out servicing of lubrication system. 7.2.4 Carry out servicing of air and exhaust system. 7.2.5 Carry out servicing of fuel system.

12

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Total Hours 36 84

73


Plant Layout/Workplace/Shop Floor, Safety Handbook, Equipment Safety Manual, Emergency and Hazardous Signage, Standard Operating Procedure, Manual Operation, Job order, assembly drawing and specification sheet, Working table, Chain block with webbing slings, shackle, wire rope, Lifting accessories, grease and diesel engine













ISBN: 0-7668-2695-3

Manuals :

2

2.5. Carta Profil

SECTOR OIL & GAS

SUB SECTOR ENGINEERING

JOB AREA MECHANICAL PLANT MAINTENANCE

JOB LEVEL THREE (3) JOB AREA CODE OGM-D15-3

CORE

STATIC EQUIPMENT WORKS

SUPERVISORY

INVENTORY MANAGEMENT

OG-015-3:2012-C04

OG-015-3:2012-C05

CORE AIDED VALUE

ON-JOB TRAINING

07A

COMPETENCY COMPETENCY UNIT

3

2.6. Carta Aliran Latihan


SEMESTER 4

BERSAMBUNG

DARI SEMESTER 3

Prepare critical

spare parts list

05.02 2/3

Identify critical

spare parts

05.01 1/3

Verify spare parts /

materials received

05.03 3/3

INVENTORY

MANAGEMENT

A18-04-03 STATIC EQUIPMENT

WORKS

SUPERVISION

A18-04-01

Supervise the

removal and

installation of heat

exchanger tube

bundle

04.01 1/4

Supervise unfired

pressure vessel

repair

04.02 2/4

Conduct Job Safety

Analysis (JSA)

related to Plant

Mechanical

Activities 04.03 3/4

Implement safety

measures at

workplace

04.07 4/4

SUPERVISORY

MANAGEMENT

A18-04-02

Coordinate

mechanical

maintenance team

04.04 1/5

Prepare technical

report

04.09 3/5

Conduct staff

training

04.05 4/5

Perform staff

appraisal

04.06 5/5

Carry out customer

and inter

departmental

liaison

04.08 2/5

END

Perform on-job

training

07A.01 1/1

ON-JOB

TRAINING

A18-04-04

4

2.7. Carta Perbandingan


SEMESTER 4

STA

TIC

EQ

UIP

MEN

T

WO

RK

S SU

PER

VIS

ION

SUP

ERV

ISO

RY

MA

NA

GEM

ENT

INV

ENTO

RY

MA

NA

GEM

ENT

ON

-JO

B T

RA

ININ

G

CU

NO

.

CU TITLE CU WORK ACTIVITIES

WA

N

UM

BER

A1

8-0

4-0

1

A1

8-0

4-0

2

A1

8-0

4-0

3

A1

8-0

4-0

4

4

STATIC EQUIPMENT

WORKS SUPERVISION

Supervise the Removal and Installation of Heat Exchanger Tube Bundle

04.01

Supervise unfired pressure vessel repair 04.02

Conduct Job Safety Analysis (JSA) related to Plant Mechanical Activities

04.03

Coordinate mechanical maintenance team. 04.04

Conduct staff Training 04.05

Perform staff appraisal 04.06

Implement safety measures at workplace 04.07

Carry Out Customer and Inter Departmental Liaison

04.08

Prepare technical report 04.09

5 INVENTORY

MANAGEMENT

Identify critical spare parts. 05.01

Prepare Critical Spare Parts list. 05.02

Verify spare parts/ materials received 05.03

07A ON-JOB TRAINING Perform on-job training 07A.01

NOSS (New Format)

JTM SYLLABUS

5

2.8. Jadual Pembahagian Jam Kredit

A18 SIJIL TEKNOLOGI MINYAK DAN GAS (MECHANICAL PLANT-DOWNSTREAM) – SEMESTER 4

KOD MODUL TAJUK MODUL

TASK JAM KREDIT

A/(PEMBERAT (1.5) X 20 )

TEORI (JAM)

AMALI (JAM)

JAM KREDIT TEORI

JAM KREDIT AMALI

JUMLAH JAM

KREDIT

KREDIT MODUL

A18-04-01 Static Equipment Works Supervision 45.0 75.0 1.5 2.5 4.0 4

A18-04-02 Supervisory Management 63.0 57.0 2.1 1.9 4.0 4

A18-04-03 Inventory Management 18.0 12.0 0.6 0.4 1.0 1

A18-04-04 On-Job Training (3 bulan) 150.0 5.0 5.0 5

JUMLAH LATIHAN ( SUBJEK TERAS ) 126.0 294.0 2.7 11.3 14.0 14

PERATUS LATIHAN ( SIJIL ) 30% 70%

JUMLAH KESELURUHAN LATIHAN 420 14

16


A18-04-01 : MECHANICAL TRANSMISSION OVERHAUL Terminal Performance Objective:



LE 1 : PERFORM GEAR BOX OVERHAUL

LE 2 : PERFORM ALIGNMENT OF COMPRESSOR

17

LE3 : PERFORM ALIGNMENT OF STEAM / GAS TURBINE

Perform alignment of steam / gas turbines using equipment safety manual, water tank, piping system, assembly drawing and working table so that Job Safety Analysis (JSA) prepared, Permit to Work (PTW) raised, cause of failure identified, Steam/gas turbine alignment carried out , de-isolation completed and maintenance report updated in accordance with company standard for maintenance job.

18


A18-04-02 : PUMP OVERHAUL Terminal Performance Objective:



LE 1 : ASSEMBLY MULTI-STAGE CENTRIFUGAL PUMP

LE 2 : SERVICE AND TESTING OF MECHANICAL SEAL

LE 3 : PERFORM TROUBLESHOOTING ON PUMP

19


A18-04-03 : COMPRESSOR OVERHAUL Terminal Performance Objective:



LE 1 :

LE 2 :

20


A18-04-04 : INTERNAL COMBUSTION OVERHAUL Terminal Performance Objective:



LE 1 :

32

SYLLABUS PROFILE




Terminal Performance Objective (TPO) Construct Engineering Drawing using plant layout, safety handbook, drawing equipment and computer so that general, piping and instrument part created in accordance with company standard and mechanical engineering (oil and gas) drafting procedure.


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LE 1 : PREPARE PART ENGINEERING DRAWING

1.1 Identify basic principle of Pipe Drawings 1.1.5 Engineering Drawing. 1.1.6 Equipment /Machine Parts 1.1.7 Equipment / Machine Part drawing.

Creating Basic Drawing using CAD software

Manipulating Objects

Altering Objects

Annotation Drawing

Hatching

4.5

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Dimensioning

Layer Management 1.1.8 Part drawing technique.

1.2 Draw using CAD software 1.2.1 Interpret Engineering Drawing. 1.2.2 Identify Parts 1.2.3 Produce Part drawing. 1.2.4 Comply Part drawing

10.5 P PT WS

LE 2 : CREATE PIPING AND INSTRUMENT DIAGRAM ( P& ID ) DRAWING

2.1 Identify pipe and instrument diagram 2.1.1 Piping and Instrument Drawing (P&ID)

Flow diagram usage

Piping Arrangement

Piping symbol 2.1.2 Part drawing Technique

Flow plan arrangement

Flow diagram instrument

Pipe and instrument diagram drawing creating techniques

13.5

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CoCu / Task No. : OG-015-1:2012-C09 / 09.01



2.1.3 Part in piping system.

Type and material for gasket

Type of valves and instruments 2.1.4 Piping Part drawing

Isometric Projection

2.1.5 Interpret Piping and Instrument Drawing (P&ID) 2.1.6 Identify Piping Parts. 2.1.7 Produce Piping Part drawing 2.1.8 Identify Type and material for gasket. 2.1.9 Identify type of valves and instruments. 2.1.10 Comply Piping Part drawing.

31.5

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WS

Total Hours 18 42

35



7. Roy A. Parisher, Robert A. Rhea (2000), Pipe Drafting and Design (2nd Edition), Gulf Professional Publishing, ISBN 13: 978-0-7506-7439

8. Richard J. Beale, Paul Bowers, Peter Smith (2010), Plant Layout And Construction Design, Gulf Publishing Company, ISBN-10: 1933762373, ISBN-13: 978-193376237





Manuals :

36

SYLLABUS PROFILE




Terminal Performance Objective (TPO)

Carry out Workshop Practise using precision measuring equipment, gasket sheet, gasket cutter, hole punch, sniper, fittings equipment, oxy-acetylene, gas cutting set, drilling machine, tap and dies set, broken bolts extractor and related drawings so that work piece measurement performed, gasket, cold and hot cutting performed, key fitting of hub / shaft installation performed, equipment components drilled and broken stud bolts extracted in accordance with company standard for maintenance job.


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LE 1 : PERFORM WORK PIECE MEASUREMENT

1.1.1 Metric and Imperial Units. 1.1.2 Type of the measuring tools:

Straight Edge

Spirit Level

Steel Rule

Feeler Gauge

Vanier Calliper

4.5

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Outside Micrometer

Dial Gauge

Bore gauge

Depth gauge 1.1.3 Measuring techniques

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1.2.1 Use of the measuring tools 1.2.2 Apply metric and imperial units. 1.2.3 Apply measuring technique 1.2.4 Measure Inside diameter, depth of grooves and length of a work piece. 1.2.5 Measure shaft outside diameter and shaft run 1.2.6 Verify surface flatness

6

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LE 2 : PERFORM GASKET CUTTING

2.1.1 Tools usage and selection 2.1.2 Measurement techniques 2.1.3 Marking techniques

steel ruler/tape

divider

compass 2.1.4 Gasket cutting techniques/methods 2.1.5 Gasket usage and selection

3

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2.2.1 Prepare tools, equipment and materials. 2.2.2 Apply measurement and marking technique. 2.2.3 Mark gasket sheet and cut. 2.2.4 Perform measurement/ sketch. 2.2.5 Use Gasket cutter, hole punch and sniper.

6

P

PT

WS

LE 3 : PERFORM COLD CUTTING

3.1.1 Materials usage and selection 3.1.2 Tools usage and selection 3.1.3 Technical drawing/sketch 3.1.4 Measurement work piece to cut technique. 3.1.5 Coolant selection 3.1.6 Cutting techniques

3

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3.2.1 Prepare tools, equipment and materials. 3.2.2 Mark and secure work piece prior cutting. 3.2.3 Cut work piece to size. 3.2.4 Select correct tools/equipment and materials 3.2.5 Read and interpret technical drawing/sketch 3.2.6 Use vice, clamps and measurement tools 3.2.7 Perform layout/mark out 3.2.8 Do measurement/sketch

6

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PT

WS

LE 4 : PERFORM HOT CUTTING

4.1.1 Materials usage and selection 4.1.2 Tools/equipment usage and selection 4.1.3 Cutting technologies guidelines. 4.1.4 Technical drawing/sketch 4.1.5 Measurement work piece to cut 4.1.6 Cutting techniques

1.5

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4.2.1 Prepare tools, equipment and materials. 4.2.2 Select correct tools/equipment and materials 4.2.3 Read and interpret technical drawing/sketch 4.2.4 Perform layout/mark out 4.2.5 Do measurement/sketch 4.2.6 Mark and secure work piece prior cutting. 4.2.7 Cut work piece to size. 4.2.8 Use vice, clamps and measurement tools

6

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PT

WS

LE 5 : PERFORM KEY FITTING TO HUB/ SHAFT INSTALLATION

5.1.1 Measurement techniques 5.1.2 Measuring tools 5.1.3 Cold cutting techniques 5.1.4 Material selection 5.1.5 File selection 5.1.6 Filing techniques

1.5

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5.2.1 Dimensions for key way measure. 5.2.2 Material for key selected and cut to size. 5.2.3 Perform Final key fitting 5.2.4 Use measuring tools 5.2.5 Mark key material 5.2.6 Carry out cold cutting 5.2.7 Select material for the key 5.2.8 Perform file key to accurate size and tolerances 5.2.9 Perform fit key to key way

6

P

PT

WS

LE 6 : DRILL EQUIPMENT COMPONENTS

6.1.1 Component material 6.1.2 Marking techniques 6.1.3 Measurement techniques 6.1.4 Describe drill bite.

3

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6.2.1 Mark location of drill point on component 6.2.2 Setting up component on drill machine. 6.2.3 Drill the work piece. 6.2.4 Inspection part after drill.

6

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LE 7 : EXTRACT BROKEN STUDS

7.1.1 Type of stud. 7.1.2 Stud material. 7.1.3 Damage locates guidelines.

1.5

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7.2.1 Prepare flatness of broken stud surface 7.2.2 Extract and drill broken stud. 7.2.3 Clean internal thread

6

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WS

Total Hours 18 42

43














ISBN: 0-7668-2695-3

Manuals :

44

SYLLABUS PROFILE





Perform Rigging and Slinging using overhead crane, safety handbook, manual operation, grease, lifting and rigging tools, spares and materials so that manual slinging equipment serviced and rigging activities performed using overhead crane and manually in accordance with rigging and lifting procedure.


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LE 1 : PERFORM MANUAL LIFTING EQUIPMENT SERVICE

1.1.1 Common/special tools, spares and materials. 1.1.2 Guidelines/ steps/ work of Manual Lifting Equipment manual instructions :-

Checklist / maintenance manual

Cause and defects/ faults of component parts guidelines

Lubrication method

Testing and acceptance criteria notes 1.1.3 Service interval guidelines

3

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1.2.1 Select appropriate tools, spares and materials. 1.2.2 Identify lifting equipment for service and testing Purposes. 1.2.3 Dismantle and assemble the lifting equipment. 1.2.4 Perform Load Test and Functional check of the lifting equipment. 1.2.5 Write a technical report 1.2.6 Execute preventive maintenance.

7

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LE 2 : PERFORM RIGGING AND MANUAL LIFTING ACTIVITIES

2.1.1 Common/special tool spares and materials 2.1.2 Weight and size of the load calculation method. 2.1.3 Type of rigging and lifting equipment guidelines:-

Safe working load (SWL) calculation method

Load to be lifted based on centre of gravity calculation

2.1.4 Rigging and Lifting procedures/guideline 2.1.5 Rigging and Lifting techniques

3

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��

2.2.6 Select appropriate lifting and rigging tools,

spares and materials 2.2.7 Identify weight and size of load. 2.2.8 Inspect physically and visually on rigging and

lifting equipment 2.2.9 Interpret rigging and lifting activities procedure 2.2.10 Ensure load and rigging equipment are secured

7

P PT WS

LE 3 : PERFORM RIGGING AND LIFTING USING OVERHEAD CRANE

3.1.8 Common/special lifting tools, spares and

materials. 3.1.9 Weight and size of load calculation method. 3.1.10 Type of rigging and lifting equipment

(overhead type) for the specified job. 3.1.11 Safe working load (SWL) calculation method. 3.1.12 Load to be lifted based on Centre of Gravity

calculation 3.1.13 Rigging and Lifting procedures/guideline 3.1.14 Rigging and Lifting techniques

3

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3.2.1 Select appropriate lifting and rigging tools, spares and materials. 3.2.2 Determine weight and size of load with Overhead Crane. 3.2.3 Inspect physically and visually on rigging and lifting equipment 3.2.4 Comply to rigging and lifting activities procedure 3.2.5 Verify load and rigging equipment are secured.

7

P

PT

WS

Total Hours 9 21

48


Plant Layout/Workplace/Shop Floor, Safety Handbook, Equipment Safety Manual, Emergency and Hazardous Signage, Standard Operating Procedure, Manual Operation, Job order, assembly drawing, specification sheet, Working table, Chain block with webbing slings, shackle, wire rope, Lifting accessories and grease.













ISBN: 0-7668-2695-3

Manuals :

49

SYLLABUS PROFILE





Carry out Piping System and Equipment Isolation using safety handbook, manual operation, appropriate equipment, grease and checklist so that preventive maintenance on valves, strainers cleaning, re-gasketing, spading, valves replacement, positive isolation and blinding activities performed in accordance with company standard for maintenance job and manuals.


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LE 1 : PERFORM PREVENTIVE MAINTENANCE ON VALVES

1.1.2 Preventive Maintenance (PM) schedule 1.1.2 Valves type, function and component :-

Technical drawing/sketch

Valve operation.

Valve parts.

Tightening procedure/method

Blast and paint valve technique.

Valve construction and parts.

6

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1.1.3 Cleaning method technique.

Dirt, sludge, rust guidelines. 1.1.4 Sealing mechanism.

Type of sealing material 1.1.5 Valve lubrication method

Types of grease.

Identify packing and greasing points 1.1.6 Check list.

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1.2.1 Check valve external condition 1.2.2 Clean valve external components 1.2.3 Perform visual inspection 1.2.4 Select cleaning agent 1.2.5 Identify packing position 1.2.6 Prepare check list/report 1.2.7 Update maintenance checklist

15

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LE 2 : PERFORM STRAINERS CLEANING AND REPAIR

2.1.1 Type of strainer 2.1.2 Material of construction 2.1.3 Strainer assembly and dismantle method. 2.1.4 Pressure Rating and size 2.1.5 Product Manual

6

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2.2.1 Prepare tools, equipment and materials 2.2.2 Dismantle Strainer 2.2.3 Clean strainer. 2.2.4 Perform Repair works on strainer. 2.2.5 Assemble strainer

9

P PT WS

LE 3 : PERFORM RE-GASKETING, SPADING / DE-SPADING

3.1.1 Types Of Gasket 3.1.2 Gasket Materials 3.1.3 Area of application 3.1.4 Types Of Sealant 3.1.5 Pipe flange blind method.

4.5

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3.2.1 Prepare tools, equipment and materials. 3.2.2 Carry out blinding 3.2.3 Insert gasket pipe flanges. 3.2.4 Making and install gasket. 3.2.5 Remove pipes flange blind

12

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LE 4 : PERFORM VALVES REPLACEMENT

4.1.1 Pressure reliving devices external condition. 4.1.2 Pressure reliving devices external components. 4.1.3 Re-painting pressure reliving device guidelines. 4.1.4 Maintenance procedure.

4.5

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4.2.5 Check pressure reliving devices external

condition. 4.2.6 Clean Pressure reliving devices external

components. 4.2.7 Re-painting pressure reliving devices. 4.2.8 Update Maintenance checklist.

12

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LE 5 : PERFORM POSITIVE ISOLATION AND BLINDING ACTIVITIES

5.1.1 Materials usage and selection 5.1.2 Tools/equipment usage and selection 5.1.3 Equipment and PI&D drawing 5.1.4 Process parameters 5.1.5 Blinding and spading list 5.1.6 Equipment isolation and de-isolation procedure.

6

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5.1.7 Blinding procedure. 5.1.8 Break flange procedure. 5.1.9 Drum and separator product. 5.1.10Joint Isolation /blinding of flange procedure. 5.1.11Re install joints after completion of all work procedure. 5.1.12Pressure Vessel product. 5.1.13Ventilation function and procedures 5.1.14Line colour coding 5.1.15Type of tower and column 5.1.16Structure of tower and column 5.1.17Construction of tower and column 5.1.18 Internal hazard in tower and column. 5.1.20Type of transmission 5.1.21Type of Lubricant 5.1.22Transmission Part and components 5.1.23 Isolation/ blinding of flange joints procedure. 5.1.24Heat exchanger 5.1.25Transmission drawing

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5.2.1 Prepare tools, equipment and materials. 5.2.2 Carry out isolation/blinding of flange joints. 5.2.3 Read and interpret equipment and PI&D drawing. 5.2.4 Install blind / spade and correct gasket. 5.2.5 Perform Drum and separator product. 5.2.6 Accesses work area.. 5.2.7 Joint Isolation /blinding of flange. 5.2.8 Open Manhole and vent cover. 5.2.9 Perform Ventilate vessel 5.2.10Assess work area to equipment plot/ plant layout. 5.2.11Ventilate column and tower. 5.2.12Carry out Heat exchanger is ventilated. Carry out Joints are re-instated after completion of all work.

15

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Total Hours 27 63

56


Plant layout/workplace/shop floor, Safety handbook, Equipment safety manual, emergency and hazardous signage, Standard operating procedure , Manual operation, Job order, assembly drawing and specification sheet, Working table, Chain block with webbing slings, shackle, wire rope, Lifting accessories, grease, Job order, assembly drawing and specification sheet, Small size centrifugal pump fitted with single mechanical seal for water service, Small size magnetic or sealers pump, Water tank and piping system .













ISBN: 0-7668-2695-3

Manuals :

57

SYLLABUS PROFILE





Carry out Static Equipment Maintenance using plant layout, safety handbook, equipment safety manual, emergency and hazardous signage, standard operating procedure, chain block with webbing slings, shackle, wire rope, lifting accessories, grease, drum (pressure vessel), column, shell and tube heat exchanger and storage tank so that preventive maintenance for pressure vessel, column, heat exchanger and storage tank performed in accordance with company standard for maintenance job.


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LE 1 : PERFORM PREVENTIVE MAINTENANCE FOR PRESSURE VESSEL

1.1.1 Permit to Work 1.1.2 Lubrication schedule. 1.1.3 Lubricants types and quantity. 1.1.4 Tools required. 1.1.5 Lubrication level setting guidelines. 1.1.6 Pressure vessel function and construction. 1.1.7 Types of maintenance. 1.1.8 Maintenance document record.

7.5

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1.2.1 Select and obtain lubricant, tools & consumable 1.2.2 Identify required checklist and manual. 1.2.3 Check Pressure vessel external condition. 1.2.4 Locate lubrication points 1.2.5 Clean Pressure vessel external components. 1.2.6 Check and confirm pressure vessel grounding. 1.2.7 Update Maintenance checklist

16.5

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LE 2 : PERFORM PREVENTIVE MAINTENANCE FOR COLUMN

2.1.1 Permit to Work 2.1.2 Lubrication schedule. 2.1.3 Lubricants types and quantity. 2.1.4 Tools required. 2.1.5 Preventive maintenance checklist. 2.1.6 Lubrication level setting. 2.1.7 Lubrication points. 2.1.8 Column function and construction. 2.1.9 Column operating parameters (temperature, noise) 2.1.10Types of maintenance. 2.1.11Maintenance document record.

6

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��

2.2.1 Select and obtain lubricant, tools & consumable 2.2.2 Prepare Permit to work 2.2.3 Identify required checklist and manual. 2.2.4 Check column external condition. 2.2.5 Locate lubrication points 2.2.6 Use lubrication equipment 2.2.7 Clean column external components. 2.2.8 Check and confirm column grounding. 2.2.9 Update Maintenance checklist

15

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LE 3 : PERFORM PREVENTIVE MAINTENANCE FOR HEAT EXCHANGER

3.1.1 Permit to Work Lubrication schedule. 3.1.2 Lubricants types and quantity.

Lubrication level setting.

Lubrication points 3.1.3 Tools required. 3.1.4 Heat exchanger function and construction.

Heat exchanger operating parameters (temperature, noise)

3.1.5 Types of maintenance. 3.1.6 Maintenance document record.

7.5

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3.2.1 Select and obtain lubricant, tools & consumable 3.2.2 Identify required checklist and manual. 3.2.3 Check heat exchanger external condition. 3.2.4 Locate lubrication points 3.2.5 Use lubrication equipment 3.2.6 Clean heat exchanger external components. 3.2.7 Check and confirm heat exchanger grounding. 3.2.8 Update Maintenance checklist

16.5

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LE 4 : PERFORM PREVENTIVE MAINTENANCE FOR STORAGE TANK

4.1.1 Permit to Work. 4.1.2 Tools required. 4.1.3 Preventive maintenance checklist. 4.1.4 Storage tank function and construction. 4.1.5 Types of maintenance. 4.1.6 Maintenance document record.

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4.2.1 Select and obtain lubricant, tools & consumable 4.2.2 Identify required checklist and manual. 4.2.3 Check heat storage tank condition. 4.2.4 Clean heat storage tank components. 4.2.5 Update Maintenance checklist

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Total Hours 27 63

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Plant layout/workplace/shop floor, Safety handbook, Equipment safety manual, emergency and hazardous signage, Standard operating procedure, Manual operation, Job order, assembly drawing and specification sheet, Working table, Chain block with webbing slings, shackle, wire rope, Lifting accessories, grease, Drum (pressure vessel), Column, Shell & tube heat exchanger, Storage tank, Centrifugal pump using mechanical seal, Positive displacement pump and Magnetic (seal less) pump.













ISBN: 0-7668-2695-3

Manuals :

62

SYLLABUS PROFILE





Carry out Mechanical Transmission Maintenance using plant layout, safety handbook, equipment safety manual, emergency and hazardous signage, standard operating procedure, chain block with webbing slings, shackle, wire rope, lifting accessories and grease so that transmission part lubrication, sprockets/belts/chain services/repair/replacement and preventive maintenance on transmission equipment performed in accordance with company standard for maintenance job.


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LE 1 : PERFORM TRANSMISSION PART LUBRICATION

1.1.1 Permit to work 1.1.2 Lubrication schedule. 1.1.3 Lubricants types and quantity. 1.1.4 Lubrication tools / equipment. 1.1.5 Lubricants types and quantity. 1.1.6 Document record.

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1.2.1 Select and obtain lubricant, tools & consumable. 1.2.2 Identify greasing points and parts to be

lubricated. 1.2.3 Apply lubrication with the correct lubricant type

and quantity. 1.2.4 Record work activities

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LE 2 : PERFORM SPROCKETS/ BELTS/ CHAIN SERVICES/ REPAIR/ REPLACEMENT

2.1.1 Tools and spare part. 2.1.2 Sprocket belt and chain. 2.1.3 Remove and reinstall sprocket, pulley and belt

and chain procedure

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2.2.1 Prepare tools and spare part. 2.2.2 Check sprocket , belt and chain 2.2.3 Remove and reinstall sprocket, pulley, belt and

chain.

7.5

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LE 3 : PERFORM PREVENTIVE MAINTENANCE ON TRANSMISSION EQUIPMENT

3.1.1 Transmission equipment external condition. 3.1.2 Clean transmission equipment external

components procedure. 3.1.3 Maintenance checklist.

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3.2.1 Check transmission equipment external

condition. 3.2.2 Clean transmission equipment external

components 3.2.3 Perform update maintenance checklist.

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Total Hours 9 21

65


Plant layout/workplace/shop floor, Safety handbook, Equipment safety manual, emergency and hazardous signage, Standard operating procedure, Manual operation, Job order, assembly drawing and specification sheet, Working table, Chain block with webbing slings, shackle, wire rope, Lifting accessories, grease, Job order, assembly drawing and specification sheet, Small size centrifugal pump fitted with single mechanical seal for water service, Small size magnetic or sealers pump, Water tank and piping system













ISBN: 0-7668-2695-3

Manuals :

66

SYLLABUS PROFILE





Carry out Rotating Equipment Maintenance using plant layout, safety handbook, equipment safety manual, emergency and hazardous signage, standard operating procedure, chain block with webbing slings, shackle, wire rope, lifting accessories, grease, pumps, compressor, blower, fan, steam/gas turbine, internal combustion engine, petrol and diesel engine so that preventive maintenance on pumps, compressor, blower, fan, steam/gas turbine, internal combustion engine and positive displacement pumps overhaul performed in accordance with company standard for maintenance job.


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LE 1 : PERFORM PREVENTIVE MAINTENANCE ON PUMPS

1.1.1 Lubrication schedule. 1.1.2 Lubricants types, quantity and method manual. 1.1.3 Tools list. 1.1.4 Preventive maintenance checklist. 1.1.5 Pump function and construction, operating

parameters (temperature, noise) 1.1.6 Maintenance document record.

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1.2.1 Remove and re install sprocket, pulley belt and

chain. 1.2.2 Carry out preventive maintenance work 1.2.3 Select and obtain lubricant, tools & consumable 1.2.4 Locate lubrication points 1.2.5 Use lubrication equipment 1.2.6 Fill in PM checklist form 1.2.7 Record findings

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LE 2 : PERFORM POSITIVE DISPLACEMENT PUMPS OVERHAUL

2.1.1 Lubrication schedule. 2.1.2 Lubricants types, quantity and method. 2.1.3 Tools required. 2.1.4 Preventive maintenance checklist. 2.1.5 Pump function and construction. 2.1.6 Pumps operating

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2.1.1 Prepare tools and materials 2.1.2 Dismantle and clean the pump parts. 2.1.3 Re- assembles the pump parts. 2.1.4 Run test the pump

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LE 3 : PERFORM PREVENTIVE MAINTENANCE ON COMPRESSOR

3.1.1 Tools, equipment and materials 3.1.2 Lubrication type and quantity 3.1.3 Preventive maintenance checklist 3.1.4 Maintenance procedures 3.1.5 Basic compressors, working principles 3.1.6 Report writing

4.5

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instruction manual. 3.2.3 Identify Preventive maintenance checklist 3.2.4 Follow the PM checklist 3.2.5 Fill in PM checklist 3.2.6 Record findings

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LE 4: PERFORM PREVENTIVE MAINTENANCE ON BLOWER

4.1.1 Tools, equipment and materials 4.1.2 Lubrication type and quantity 4.1.3 Preventive maintenance checklist 4.1.4 Maintenance procedures 4.1.5 Basic blower working principles 4.1.6 Report writing

4.5

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4.2.1 Prepare tools and materials according Work procedure.

4.2.2 Perform Preventive Maintenance according to instruction manual.

4.2.3 Identify Preventive maintenance checklist 4.2.4 Follow the PM checklist 4.2.5 Fill in PM checklist 4.2.6 Record findings

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LE 5: PERFORM PREVENTIVE MAINTENANCE ON FAN

5.1.1 Tools, equipment and materials 5.1.2 Lubrication type and quantity 5.1.3 Preventive maintenance checklist 5.1.4 Maintenance procedures 5.1.5 Basic fan working principles 5.1.6 Report writing

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instruction manual. 5.2.3 Identify Preventive maintenance checklist 5.2.4 Fill in PM checklist

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LE 6: PERFORM PREVENTIVE MAINTENANCE ON STEAM / GAS TURBINE

6.1.1 Introduction Gas and Steam Turbine. 6.1.2 Tools and materials. 6.1.3 Preventive maintenance work. 6.1.4 Maintenance checklist.

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6.2.1 Prepare tools and materials. 6.2.2 Perform preventive maintenance work. 6.2.3 Update and complete preventive maintenance

checklist.

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LE 7: PERFORM PREVENTIVE MAINTENANCE ON INTERNAL COMBUSTION ENGINE

7.1.1 Tools and materials. 7.1.2 Cooling water system. 7.1.3 Combustion Engine lubrication system. 7.1.4 Servicing of air and exhaust system guidelines 7.1.5 Fuel system in Combustion Engine.

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7.2.1 Prepare tools and materials. 7.2.2 Inspect and service Cooling water system. 7.2.3 Carry out servicing of lubrication system. 7.2.4 Carry out servicing of air and exhaust system. 7.2.5 Carry out servicing of fuel system.

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Total Hours 36 84

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Plant Layout/Workplace/Shop Floor, Safety Handbook, Equipment Safety Manual, Emergency and Hazardous Signage, Standard Operating Procedure, Manual Operation, Job order, assembly drawing and specification sheet, Working table, Chain block with webbing slings, shackle, wire rope, Lifting accessories, grease and diesel engine













ISBN: 0-7668-2695-3

Manuals :

silibus a18 (l3)

Documents