Course Outline
1. Understand and apply OSHA regulations and practices to perform work tasks safely.
a. Introduction to OSHA
b. Electrical Safety
c. Walking and working surfaces
d. Exit routes
e. Emergency action plans
f. Fire prevention plans
g. Fire protection
h. Material handling/back injury prevention
i. Flammable and combustible liquids
j. Personal protective equipment (PPE)
k. Machine guarding
l. Hazard Communication
m. Blood-borne pathogens
2. Identify and select structural metal shapes and metal plates from technical drawings.
a. Recognize and understand how symbols and notes are used to identify common steel shapes on technical drawings.
b. Recognize common metal shops by geometric profile (W-beams, Angles, T-beams, etc.).
c. Recognize and understand how symbols and notes are used to identify common metal plates and sheet metal on technical drawings.
d. Understand the correlation between metal thickness and common gauge and plate standards.
3. Illustrate common techniques used to cut metal shapes and plates in preparation for assembly.
a. Understand Oxy-fuel and plasma torch cutting.
b. Understand the use of various types of saws.
c. Understand the use of various types of sheers.
4. Illustrate how to use common equipment and tools to contour, bend, notch, punch, or drill structural metal shapes and plates.
a. Understand the use of various types of Numerical Control (NC)/Computerized Numerical Control (CNC) machines (plasma, laser, water-jet, etc.) used to cut profiles from stock materials.
b. Understand the use of various types of presses to bend or punch holes in profiles.
c. Understand the use of various types of vertical and horizontal drill presses and boring machines to place holes in profiled plates and structural members.
d. Understand the use of various types saws used to profile plates and shapes.
5. Illustrate how common welding techniques, equipment, and tools are used to join metal shapes and plates.
a. Understand the general use of stick-electrode, Gas Metal Arc Welding (GMAW), and Tungsten Inert Gas (TIG) for joining metals.
b. Understand the general equipment used of stick-electrode, Gas Metal Arc Welding (GMAW), and Tungsten Inert Gas (TIG) for joining metals.
6. Demonstrate the ability to assemble and inspect basic metal assemblies and sub-assemblies for accuracy and quality.
a. Demonstrate the usage of technical drawings, technical instructions, and measuring tools to assemble a pre-defined component to an acceptable state.
b. Assemble and disassemble a box using standard operating procedures (SOP).
7. Demonstrate knowledge of basic chemistry principles required to meet process technology work goals.
a. Describe the basic properties of common chemicals used and produced in processing plants.
b. Describe what acids and bases are, and the hazards of each.
c. Explain how these chemicals are sometimes common in the home.
d. Describe distillation and reaction.
8. Demonstrate knowledge of basic physics principles required to meet process technology work goals.
a. Describe the basic principles of pressure.
b. Describe the basic principles of temperature and how it relates to pressure.
c. Examine the basics of fluid flow and how it relates to process equipment.
d. Contrast and compare specific gravity and density.
e. Solve simple pressure, temperature, and flow conversions.
9. Explain the history of process technology and its terminology.
a. Explain the history of the refining process and its terminology.
b. Explain the history of the chemical process and its terminology.
c. Explain the history of the automobile process and its terminology.
d. Explain the history of the steel process and its terminology.
10. Explain the function of process technology equipment and tools.
a. Explain the purpose and function of basic hand tools.
b. Explain the purpose and function of piping and valves.
c. Explain the purpose and function of pumps and compressors.
d. Explain the purpose and function of furnace and boilers.
e. Explain the purpose and function of heat exchangers and cooling towers.
f. Explain the purpose and function of distillation and reactors.
g. Explain the purpose and function of safety and relief valves.
11. Demonstrate operation of basic process controls.
a. Explain Process Flow Diagrams (PFDs) and Piping and Instrumentation Diagrams (P&IDS) and their symbols.
b. Discuss the differences between set points and process variables.
c. Explain the purpose and function of basic process instrumentation.
d. Explain the purpose and function of a basic control loop and its equipment.
e. Explain the purpose and function of interlocks and permissives.
(Tools and Equipment)
1. Demonstrate safe and correct usage of hand tools.
a. Demonstrate safe and correct usage of striking tools.
b. Demonstrate safe and correct usage of struck tools.
c. Demonstrate safe and correct usage of shaping tools.
d. Demonstrate safe and correct usage of cutting tools.
e. Demonstrate safe and correct usage of turning/tightening tools.
2. Demonstrate safe and correct usage of power tools.
a. Describe the purpose and use of GFCIs
b. Describe the purpose and importance of proper tool grounding.
c. Demonstrate safe and correct usage of rotating tools.
d. Demonstrate safe and correct usage of reciprocating tools.
e. Demonstrate safe and correct usage of special tools.
3. Identify and show how symbols are used in drawings, including prints and schematics.
a. Identify hydraulic symbols.
b. Identify pneumatic symbols.
c. Identify electrical symbols.
d. Identify the drawing date, revision level etc. of a drawing or print.
e. Determine the linear, angular, and radii tolerances of parts from the drawing.
4. Identify the basic components of a hydraulic system using a schematic.
a. Identify various types of pumps.
b. Identify various safety components of a hydraulic system.
c. Identify various types of regulators/compensators.
d. Identify various types of actuators (rotary and linear).
e. Name component symbols used on hydraulic schematics.
f. Explain the basic flow path of a hydraulic system.
5. Illustrate practical applications and maintenance procedures for hydraulic systems.
a. Discuss a hydraulic system located on automobiles.
b. Describe equipment installed in Power Braking systems to ensure adequate hydraulic pressure is supplied to the brakes and to notify the operator if a brake failure has occurred.
c. Explain why air in a power braking system causes the brakes to fail.
d. Discuss a hydraulic system support for conveyor movement.
e. Describe the steps required to maintain the hoses and tubing carrying oil to cylinders and pistons.
f. Discuss the importance of clean oil to smooth operation of conveyors.
6. Analyze hydraulic system problems.
a. Demonstrate ability to recognize the problem then initiate steps to remove air from a hydraulic system.
b. Demonstrate ability to observe the oil for contamination or debris, inspect the filters, then replace the filters as needed.
c. Explain the steps taken should a fine mist (yellow smoke) appear around a hydraulic system.
d. Demonstrate ability to solve problems associated with slow reaction from hydraulic system.
7. Identify the basic components of a pneumatic system using a schematic.
a. Identify various types of compressors.
b. Identify various safety components of a pneumatic system.
c. Identify various types of regulators/compensators.
d. Identify various types of actuators (rotary and linear).
8. Demonstrate the ability to assemble the basic components of a pneumatic system.
a. Draw a flow diagram naming the basic components of a pneumatic system.
b. Explain the basic flow path of a pneumatic system.
c. Identify tools required to perform maintenance on a pneumatic system.
d. Connect the components of a pneumatic system using approved tools, tubing, and fittings.
9. Analyze pneumatic system problems.
a. Demonstrate the ability to diagnose a problem with the air intake causing low air pressure supplied to the pneumatic system.
b. Determine the cause of moisture build-up in the main air lines, dryer, and after cooler.
c. Demonstrate the ability to diagnose a problem with unwanted oil in the compressed air at the point of use.
d. Demonstrate the ability to identify and close the correct valves to isolate components when troubleshooting pneumatic system problems.
e. State the possible causes for a sudden pressure loss, a mist seen, or a hissing noise heard in a pneumatic system.