EN-2111 - Auxiliary Machinery II

TOPIC - Basic steam table

• Understands the terminology associated with, and is able to look up the heat values for saturated water or steam at a given temperature and pressure.
• Understands the relation between quantity of heat added, change of state, and change in temperature.
• Reviews conversion of PSIG to PSIA.

TOPIC - Traps, drains, strainers

• Understands the use and operation of traps used in sewer drains systems.
• Knows why steam traps are used and proper installation of same.
• Knows the application of and feed system recovery points for HP, LP, and contaminated drain systems.
• Understands the construction, operation, application and maintenance requirements of mechanical, thermostatic, and thermodynamic steam traps.
• Identifies the equipment installed with a steam trap.
• Identifies the purpose of and differences between filters and strainers.
• Knows how to determine when a strainer/filter is dirty and must be cleaned or replaced.
• Understands the construction, operation, application and cleaning procedures for simplex, duplex strainers.
• Knows the detailed change-over procedure for manually operated duplex strainers and safety precautions for same.

31A6

TOPIC - Pumps, theory

• Defines purpose of pump capacity and capacity related to head.
• Explains how pumps lift.
• Defines and calculates static heads.
• Classifies and identifies basic pump types.

31A7

TOPIC - Pumps, reciprocating

• Understands terminology associated with, classification, construction, operating principles, applications, basic troubleshooting and maintenance requirements of reciprocating pumps.
• Reads and identifies component parts on blueprints.
• Calculates capacity in GPM.
• Describes pump starting, stopping and operating procedures.

31A6
31A7

TOPIC - Pumps, centrifugal

• Understands terminology associated with, classification, construction, operating principles, applications, basic troubleshooting and maintenance requirements of centrifugal pumps.
• Reads and identifies component parts on blueprints.
• Describes pump starting, stopping and operating procedures.

31A6
31A7

TOPIC - Pumps, rotary

• Understands terminology associated with, classification, construction, operating principles, applications, basic troubleshooting and maintenance requirements of rotary pumps.
• Reads and identifies component parts on blueprints.
• Describes pump starting, stopping and operating procedures.

31A6
31A7

TOPIC - Pumps, propeller

• Understands terminology associated with, classification, construction, operating principles, applications, basic troubleshooting and maintenance requirements of propeller pumps.
• Reads and identifies component parts on blueprints.
• Describes pump starting, stopping and operating procedures.

31A6
31A7

TOPIC - Pumps, jet

• Understands terminology associated with, classification, construction, operating principles, applications, basic troubleshooting and maintenance requirements of jet pumps.
• Reads and identifies component parts on blueprints.
• Describes pump starting, stopping and operating procedures.

31A6
31A7

TOPIC - Heat exchangers

• Understands terminology associated with, classification, construction, operating principles, applications, basic troubleshooting and maintenance requirements of heat exchangers.
• Identifies component parts from drawings.
• Knows how to locate and repair tube leaks.

31A6
31C1

TOPIC - Condensers

• Understands terminology associated with, types, construction, operating principles, applications, attachments, basic troubleshooting and maintenance requirements of condensers.
• Identifies component parts from drawings.
• Explains purpose of vacuum in condenser, use of recalculating lines, condenser supports, corrosion/erosion protection.
• Calculates and knows how to control condensate depression.
• Knows safety practices associated with maintenance on cooling water side.

31A6

TOPIC - Air ejectors

• Understands terminology associated with, types, purpose, construction, operating principles, applications, attachments, basic troubleshooting and maintenance requirements.
• Identifies component parts from drawings.
• Knows flow paths of coolant, steam, air, condensate drains.
• Knows use of recalculating line, purpose of loop seal drain, and purpose of gland exhaust condenser.
• Knows start-up procedure for 2 stage unit.

31A6

TOPIC - Feed water systems

• Knows evolution and purposes of feed water systems.
• Knows component locations and uses in feed water systems.
• Understands why use of extraction steam from main power turbine can increase plant efficiency by heating feed water.
• Calculates efficiency gain as a result of heating feedwater.
• Understands feed system heat balance schematic.

31A6

TOPIC - Deaerating feed tanks

• Understands terminology associated with, types, purpose, construction, operating principles, attachments and operating problems.
• Identifies component parts from drawings.
• Knows reason for high suction head on feed pump and purpose of centrifugal feed pump recalculating line.

31A6
31C1

TOPIC - Basic hydraulics

• Understands the following in relation to basic hydraulic components and systems: terminology, classification, construction, operating principles, applications, basic troubleshooting and maintenance requirements.
• Calculates transmission of forces, multiplying forces, speed, time required, etc., to produce work.
• Knows details and limits of fluids in system.
• Understands the following components: reservoirs, filters, oil coolers, pumps and motors (including radial/axial piston designs), pipe/tubing/hose, power cylinders, seals/gaskets, general valves - (directional control - sliding spool types, valve actuators, flow control, check, relief and by-pass - (direct-acting and pilot control), shuttle) and accumulators.
• Identifies standard symbols and reads basic hydraulic system drawings.

31A6
31C1

TOPIC - Air compressors

• Understands the following in relation to basic air compressors and systems: terminology, classification, construction, operating principles, applications, basic troubleshooting and maintenance requirements.
• Reads exploded view drawings.
• Understands the function, construction and use of: receivers, filter/moisture separators and lubricators.
• Understands the function, construction and use of: reciprocating compressors: multi-staging, cooling, lubrication, valves, importance of: air filters and excessive air temperatures through compressor, controls/unloaders, unloader actuators.
• Understands the function, construction and use of: rotary screw air compressor: Besides above, understands compressor capacity control system, and special coolant/lubricant system.
• Calculates capacity (in CFM) of reciprocating air compressor.

31A2
31A6
31C1

LAB - Traps, Drains, and Strainers

• Understands that a steam trap is attached to the lower portion of a steam filled line or heat exchanger. It allows the water to pass through, but not steam.
• Understands that steam traps are used on various steam systems and heat exchangers where they remove the water formed as the result of unavoidable condensation.
• Understands that a good steam trap passes all the water that flows to it without discharging any steam, is not rendered inoperative by particles of dirt or by accumulation of air, and is rugged in construction with few moving parts.
• Understands that traps have a definite inlet, outlet and top and must be installed correctly to function properly.
• Understands that gravity normally brings the water into the trap and the pressure in the system forces the water to flow through the trap.
• Understands the construction and operating principles of the following stream traps:
  • Ball float
  • Up-right bucket
  • Inverted bucket
  • Thermostatic
  • Thermodynamic
• Understands that most traps are preceded by a strainer to remove dirt and traps in critical systems are normally fitted with inlet, outlet and by-pass valves
• Understands that float type traps are frequently used to drain water from compressed air storage tanks and airlines.
• Understands the purpose and construction of simplex and duplex strainers.
• Understands the dangers in changing over and cleaning a duplex strainer.
• Understands that duplex strainers of different manufacturers indicate which strainer assembly is in service by different methods.
• Understands the importance of loosening the plug valve prior to placing the clean strainer on the line and retightening prior to cleaning the dirty strainer.
• Understands the use of cover vents and strainer drains to check for pressure.
• Understands how to loosen a strainer cover without removing the devices that hold it in place.
• Understands the problems created to down stream machinery by large air pockets in the strainer housing being placed in service.
• Understands how to change over a operating duplex strainer safely.

31A2.3

LAB - Main Condensate System T.S. Enterprise

• Understands the purpose of "tracing lines".
• Understands the purpose and location of the following main condensate system components:
  • Main condenser
  • Hotwell
  • Main condensate pumps
  • Main engine air ejector
  • Gland leak-off condenser (also called Gland exhaust condenser)
  • LP feed heater & drain cooler (also called 1st stage heater)
  • DC Heater
  • Main condensate pump recirculating valve and line.
• Understands the purpose and location and number of distill water tanks
• Understands the purpose and location and number of reserve feed tanks
• Knows the number and type of main condensate pumps
• Knows the normal operating temperature and pressure in the DC heater
• Knows the source of steam to operate the DC heater
• Knows what makes it operate and the purpose of the Automatic make-up feed valve. Also where the water comes from to this valve and where it can be sent to after this valve
• Knows what makes it operate and the purpose of the Automatic excess feed (dump) valve. Also where the water comes from to this valve and where it is sent to after the valve
• Knows where the auxiliary condensate system ties into the main system
• Knows the locations where make-up feed can be added to the steam plant
• Knows what condenses the steam in the main condenser
• Understands that equipment installed in a critical piping system must be fitted inlet and outlet valves and a by-pass line and valve

31A6
31C1.1.1

LAB - Basic hydraulics

31A2.3

TOPIC - Basic Principles of Hydraulics

• Understands that liquids have no shape of their own.
• Understands that liquids are practically incompressible.
• Understands that liquids transmit applied pressure in all directions and act with equal force on all equal areas and at right angles to them.
• Understands that liquids provide great increases in work FORCE.
• Understands the concept that Force = Pressure * Area
• Understands that a hydraulic system has four basic components:
  • a pump
  • a cylinder or a motor which produces work
  • valves that control oil flow quantity and direction
  • a reservoir to store the oil

TOPIC - Hydraulic Systems

• Understands that the "open-center" center type system requires that the control valve spool be open in the center to allow pump flow to pass through the valve and back to the oil reservoir when hydraulic fluid is not flowing to the system.
• Understands that the open type system normally uses a constant displacement pump therefore the oil must have a path to return to the reservoir when it is not flowing to the system.
• Understands that the "closed center" system uses a control spool valve stops flow from the pump when it is in the centered position.
• Understands that the closed center system uses a variable displacement pump (can be positioned for zero discharge flow) when hydraulic fluid is not flowing to the system.

TOPIC - Advantages of Hydraulics

• Understands that the main advantage of hydraulic energy conversions is the flexibility to transmit power from the source to remote locations.
• Understands that hydraulics provide a multiplication of FORCE.
• Understands that hydraulic systems are compact, economical, simple, and safe.

TOPIC - Disadvantages of Hydraulics

• Understand that hydraulic systems are not as efficient as mechanical transmission of power but are more efficient than electrical transmission.

TOPIC - Hydraulic Valves

• Understands that there are three types of valves used in hydraulic systems:
  • pressure control valves
  • directional control valves
  • volume control valves.

LAB - Feedwater System, T.S. Enterprise

• Understands the purpose of "tracing lines"
• Understands the purpose and location of the following feed system equipment:
  • DC Heater
  • Main feed pumps
  • Inport feed pump
  • Main & auxiliary feed lines
  • Main & auxiliary feed line stop/check, regulator, & remote isolation valves
  • Boiler economizers
  • Main feed pump recirculating valves
• Understands or knows the following:
  • The destination of the water flowing through the main feed pump recirculating line
  • The purpose of the main feed pump recirculating line
  • The type of pump used as the main feed pump
  • The type of pump used as the inport feed pump
  • The suction and discharge connections on the main feed pumps
  • The suction and discharge connections on the inport feed pump
  • The normal discharge pressure of a boiler feed pump
  • The normal temperature and pressure of the main feed pump operating steam.
  • Where the main feed pump steam goes after leaving the turbine
  • The method of regulating the main feed pump discharge pressure
  • The level gages available in the engine room to monitor the feed system
    • Condenser hotwell
    • DC Heater
    • Boiler steam drum
  • The purpose of the feed water regulator
  • The signals used by the feed water regulator to control steam drum level
  • Where the feed pump pressure relief valves discharge to

31A6
31C1.1.1

LAB - Duplex, Double-acting Steam Reciprocating Pump

• Understands that the plunger in the liquid cylinder is operated directly by a steam reciprocating engine.
• Understands that the reciprocating pump is positive displacement and the discharge system must be protected against excessively high pressure by the installation of a pressure relief valve.
• Understands that positive displacement pumps do not normally have to be primed to lift liquids from below the pump.
• Understands that the reciprocating pump delivers a fixed volume of liquid when run at a constant speed.
• Understands that the reciprocating pump produces a pulsating discharge pressure and flow that may not be acceptable for some liquid systems.
• Understands that the liquid end suction and discharge check valves are operated by differential pressure.
• Understands and can read written instructions, machinery blueprints, exploded views, and cut-away diagrams.
• Understands the importance of lockout, tagout procedures.
• Understands how to use the tools required to work on steam reciprocating pumps.
• Can identify locations where normal wear occurs in the steam reciprocating pump.
• Understands how to "set" the "D" slide valves on a duplex, double-acting steam reciprocating pump for proper pump operation.
• Understands how to adjust the packing on the steam and liquid end rods.
• Understands how to properly line up the pump and place it in service.

31A2
31A7.2
31C1.1
31C1.2
31C1.2.1
31C1.3

LAB - Air Cooled, Two Stage Reciprocating Air compressor

• Understands that the uncontrolled release and expansion of compressed air is dangerous and can cause injury.
• Understands how rotary motion at the flywheel is converted to reciprocating motion at the pistons via the crankshaft and connecting rod assemblies .
• Understands that the heat from compressing the air is removed from the compressor head, cylinders and intercooler via air flow from fan blades that are part of the compressor flywheel.
• Understands the purpose of compressing air in two stages and cooling it in between stages of compression .
• Understands the purpose of and method of operation of the oil pressure actuated pneumatic suction valve unloaders.
• Understands the purpose and necessity of air suction filters.
• Understands the importance of crankcase oil level and oil pressure.
• Understands and can read written instructions, machinery blueprints, exploded views, and cut-away diagrams.
• Understands the importance of lockout, tagout procedures.
• Understands how to use the tools required to work on the reciprocating air compressors.
• Can identify locations where normal wear occurs in the reciprocating air compressor.
• Understands how the disk type suction and discharge valves are installed in the cylinder head and that they operate due to differential air pressure.
• Understands how to properly line up the air compressor and place it in service.
• Understands how to adjust the pressure switch that controls the compressor cut-in and cut-out pressures.

31A2
31A6.1.8
31C1.1
31C1.2
31C1.2.1
31C1.3

LAB - End Suction Centrifugal Pump

• Understands that centrifugal pumps are not positive displacement pumps and are usually under a Net Positive Suction Head (NPSH) or are primed.
• Understands that centrifugal pumps will develop one maximum discharge pressure for a given impeller diameter and a fixed impeller speed.
• Understands when the centrifugal pump reaches its maximum discharge pressure for a fixed speed, flow through the pump stops and the impeller churns through the liquid in the pumping chamber adding frictional heat to the liquid.
• Understands that centrifugal pumps seal the shaft area with either a packed stuffing box or with a mechanical seal.
• Understands that proper anti friction bearings, shaft alignment, impeller clearance, shaft run out, and shaft axial deflection are critical for the optimum operation and longevity of the pump.
• Understands that the impeller imparts a velocity to the fluid being pumped and the volute converts this velocity to pressure.
• Understands that open or semi-open impellers are designed to handle some solids in the liquids being pumped.
• Understands and can read written instructions, machinery blueprints, exploded views, and cut-away diagrams.
• Understands the importance of lockout, tagout procedures.
• Knows how to use the tools required to work on this type of pump.
• Can identify locations where normal wear takes place in this type of pump.
• Understands how to use a dial indicator to measure shaft deflection, shaft axial movement, and impeller to case clearance.oo
• Understands how to cut, fit and adjust conventional shaft packing.
• Understands how to line up and place a centrifugal pump in operation.

31A2
31A7.2
31C1.1
31C1.2
31C1.2.1
31C1.3

LAB - Axial Split Case Centrifugal Pump

• Understands that centrifugal pumps are not positive displacement pumps and are usually under a Net Positive Suction Head (NPSH) or are primed.
• Understands that centrifugal pumps will develop one maximum discharge pressure for a given impeller diameter and a fixed impeller speed.
• Understands when the centrifugal pump reaches its maximum discharge pressure for a fixed speed, flow through the pump stops and the impeller churns through the liquid in the pumping chamber adding frictional heat to the liquid.
• Understands that centrifugal pumps seal the shaft area with either a packed stuffing box or with a mechanical seal.
• Understands that proper anti friction bearings, shaft alignment, impeller clearance, shaft run out, and shaft axial deflection are critical for the optimum operation and longevity of the pump.
• Understands that the impeller imparts a velocity to the fluid being pumped and the volute converts this velocity to pressure.
• Understands the terms enclosed, double suction impeller as they apply tothis pump.
• Understands and can read written instructions, machinery blueprints, exploded views, and cut-away diagrams.
• Understands the importance of lockout, tagout procedures.
• Knows how to use the tools required to work on this centrifugal pump.
• Knows the proper method to remove and install a pressed fit anti-friction bearing.
• Can identify parts where normal wear occurs in this centrifugal pump.
• Understands how to use outside calipers and dial micrometers to measure impeller to casing wearing clearance and the importance of same.
• Understands the principle of operation and how to install a single unbalanced mechanical shaft seal.
• Understands how to line up and place a centrifugal pump in operation.

31A2
31A7.2
31C1.1
31C1.2
31C1.2.1
31C1.3