Online Technical Skills Catalog

Related Training & Instruction (RTI) is a critical part of industrial skills training. RCAM is equipped to provide online industrial training through courses developed by a leader in the industrial training industry, TPC Training Systems. TPC has developed an extensive course library, with hundreds of hours of relevant industrial content in a convenient online format. Each course contains individual lessons of approximately 1 hour in length. With the online learning management system (LMS), pre and post tests are available to track learning progress. 

With RCAM’s branded web-based training solution; critical technical job knowledge is available around the clock to support the training needs of individuals or organizations. The RCAM is ready to work with you or your company to develop a training plan that meets your specific objectives.

For more information, please contact the RCAM Programs & Services Coordinator at 423.354.5275.


Course Name and Description





Reading Blueprints



Covers all types of blueprints used in industrial plants. Discusses machine parts and machine drawings. Features drawings of a compound rest and a clutch-brake control. Examines hydraulic, pneumatic, piping, plumbing, electrical, air-conditioning, and refrigeration drawings. Introduces sketching used in industrial plants.



Reading Schematics and Symbols



Covers all types of schematics and symbols used in commercial and industrial settings. Examines symbols on schematics, electrical symbols and diagrams, piping symbols and diagrams, hydraulic and pneumatic diagrams and symbols. Discusses air conditioning and refrigeration systems, including explanations of electrical/electronic control schematics. Covers welding and joining symbols.



Mathematics in the Plant



Begins by introducing mathematical basics-numbers and numerals, subtraction, addition, multiplication, and division. Examines common fractions and decimal fractions, ratios and proportions, powers and roots. Discusses the calculator: usage, basic and special functions, internal logic, and special purpose calculators. Moves on to cover geometry, algebra, and formulas for problem solving. Concludes by explaining properties of triangles and trig and inverse trig functions.



Making Measurements



Covers units of measurement used in commercial and industrial applications. Examines all aspects of basic measurement concepts and procedures, including accuracy and tolerance. Discusses techniques and devices for comparison measurements (dial indicators and gauge blocks). Shows common methods for measuring volume, motion, force, temperature, fluid flow, and electricity. Explains how to use scales and rules, combination calipers, and micrometers



Metals in the Plant



Introduces metals, metallurgy, and metalworking. Discusses the properties of metals, including their mechanical properties. Examines several industrial manufacturing processes. Covers iron and standard steels. Explains the different kinds of heat treatment and their usage. Discusses some techniques of working with copper, aluminum, magnesium, titanium, lead, nickel, tin, and zinc.



Nonmetals in the Plant



Introduces major nonmetal materials and how they are most frequently used. Describes properties, characteristics, and classifications of each material. Covers synthetic and natural materials. Examines various paints and coatings, their proper use, preparation, and application. Surveys industrial chemicals. Chemical safety precautions are covered, along with the proper use of protective equipment.



Hand Tools



Covers the most important hand tools used on the job. Begins with measuring tools, including a discussion of units of measurement. Examines the various kinds of wrenches and screwdrivers, their uses and handling techniques. Explains other hand tools by specialty: pipefitting tools, plumbing tools, electrician's tools, sheet metalworking tools, machinists' metal-working tools. Ends with hoisting and pulling tools.



Portable Power Tools



Explains the uses, selection, safety, and care of industrial power tools: electric drills, electric hammers, pneumatic drills and hammers, screwdrivers, nutrunners, wrenches, linear-motion and circular saws, routers and planes, electric sanders, grinders, and shears. Covers tool sharpening techniques for selected tools.



Industrial Safety and Health



Explains government involvement in ensuring a safe workplace. Discusses safety in various situations. Discusses personal protective equipment and fire safety. Includes expanded coverage of many health hazards. Covers ergonomics, environmental responsibility and importance of maintaining a safe work environment.



Troubleshooting Skills



Explores the subject of troubleshooting and the importance of proper maintenance procedures. Covers working with others, aids in communication, and trade responsibilities. Outlines troubleshooting techniques and aids, using schematics and symbols. Focuses on specific maintenance tasks, breakdown maintenance, and planned maintenance.





Basic Electricity and Electronics



Covers basic, nonmathematical approach to understanding principles of electricity. Introduces electron theory, static electricity, electrons in motion, and magnetism. Covers basic methods of measuring current, voltage, and resistance. Explains circuit components-conductors, insulators, resistors, capacitors-and simple Ohm's Law calculations for DC and AC circuits.



Batteries and DC Circuits



Covers how electrochemical action is used. Covers batteries, electrolytic action, electroplating, Characteristics of storage batteries, application and maintenance of lead-acid, nickel-alkaline, and nickel-cadmium batteries, putting batteries into service, charging batteries, maintaining records, fundamentals of DC circuits, and using Ohm's Law to solve problems in DC series, parallel, and series-parallel circuits.



Transformers and AC Circuits



Covers differences between DC and AC circuits. Explains AC sine wave, using vectors to solve AC problems, calculating impedance in circuits having inductance, capacitance, and resistance, AC power relationships in single-phase and three-phase circuits, and principles of transformer maintenance.



Electrical Measuring Instruments



Covers the principles on which electrical test instruments operate. Basic instruments covered include voltmeter, ammeter, wattmeter, ohmmeter, and megohmmeter. Covers AC metering, split-core ammeter, use of current and potential transformers. Includes detailed coverage of modern multimeters. Explains functions and uses of oscilloscopes.



Electrical Safety and Protection



Examines electrical hazards and stresses the importance of electrical safety. Covers the equipment and procedures necessary to work safely with electricity, including PPE, lockout/tagout, and first aid. Explains the importance of grounding. Describes many kinds of fuses, circuit breakers, and motor protection devices and their uses.



DC Equipment and Controls



Covers DC power applications in industry, types of DC generators, operating characteristics of DC motors, DC armature principles, and armature maintenance and repair. Includes types of DC relays, DC controllers, overspeed and overload protection, drum and reversing controllers, dynamic braking, DC power supplies, diodes, semiconductors, SCR principles, and DC maintenance practices.



Single-Phase Motors



Covers the types and operating principles of common single-phase motors. Explains NEMA motor standards. Explains how to identify motor leads on split-phase, capacitor-start, capacitor-run, permanent split capacitor, and repulsion motors. Also covers universal motors, shaded-pole motors, and other special types, including synchro and servo systems. Gives general maintenance procedures on all single-phase motors.



Three-Phase Systems



Covers three-phase motor principles for induction, synchronous, and multi-speed dual-voltage motors. Gives recommended maintenance practices for large AC motors. Covers principles of three-phase motor starters, part winding, reversing, jogging, alternator principles and operation. Describes three-phase power distribution.



AC Control Equipment



Covers the broad range of industrial motor starting and control equipment, including NEMA sizes and ratings. Includes pushbutton control stations, limit switches, mercury switches, mechanical and magnetic plugging, foot switches, and pressure, temperature, and float switches. Covers control panel wiring and special applications.



Electrical Troubleshooting



Covers use of schematic diagrams, determining sequence of operation, and use of building diagrams and single-line diagrams. Includes troubleshooting procedures for control circuits and combination starters. Explains troubleshooting practices on DC and AC motors, identifying unmarked leads on three-phase delta and Y-connected motors, and troubleshooting lighting systems.



Electrical Safety in the Workplace—Understanding NFPA 70E®



Introduces the trainee to the purpose of NFPA 70E and explains the history of its creation. After discussing the relationship between OSHA and NFPA 70E, the course moves through the standard, article by article, highlighting the important points in each. Concludes with a lesson on the annexes and supplemental material found in the NFPA 70E Handbook.





Basic Mechanics



Covers force and motion, work and energy, and fluid mechanics as applied in industrial maintenance. Explains principles of operation for simple machines, such as the lever, inclined plane, wheel and axle, pulley, and screw. Explains the basic elements of industrial machines, as well as common measurement tools used to monitor and adjust equipment. Covers hand tools, power tools and fasteners, ending with a discussion of ways to reduce friction and wear.



Lubricants and Lubrication



Covers a complete lubrication training program, including functions and characteristics of lubricants, factors in selection of lubricants, and effects of additives. Oils, greases, and other compounds used for lubrication are described, as well as their applications. Lubrication methods and recommended storage and handling procedures are included.



Power Transmission Equipment



Covers belt drives, chain drives, gears and gear drives, adjustable-speed drives, shaft alignment, shaft coupling devices, and clutches and brakes.






Covers principles and applications of various types of bearings, including plain journal, ball, and roller bearings. Explains installation, inspection and repair of bearings. Deals with specialized bearings, including powdered-metal, nonmetallic, and hydrostatic bearings. Covers bearing seals, lubrication, and maintenance practices.






Covers typical applications of various types of pumps. Describes factors affecting pump selection. Explains operating principles of centrifugal, propeller, and turbine, rotary, reciprocating, and metering pumps. Includes special-purpose pumps, diaphragm pumps, and others designed to handle corrosive and abrasive substances. Covers pump maintenance, packing gland, seal, and bearing replacement.



Piping Systems



Covers piping and tubing systems used for fluid transport in the plant: hydraulic fluids, steam, liquefied product, refrigerant, and water. Shows typical metallic and nonmetallic piping systems, pipe-joining methods, and how tubing and hoses differ from piping. Covers valves, pipe fittings, hangers, supports, and insulation, and shows how tubing is sized, fitted, bent, and joined. Explains uses of traps, filters, and strainers.



Basic Hydraulics



Covers hydraulic principles, types of hydraulic fluids and their characteristics. Describes components of the hydraulic system and their functions, including filters and strainers, reservoirs and accumulators, pumps, piping, tubing and hoses, control valves, relief valves, and actuating devices. Covers a variety of cylinders and hydraulic motors.



Hydraulic Troubleshooting



Covers understanding the systems, using schematic diagrams, installation procedures, cleanliness and safety. Includes tubing cutting, bending, and flaring, identification and selection of proper fluid, and charging the system. Discusses planned maintenance, specific repair/replacement recommendations, system diagnosis, and troubleshooting.



Basic Pneumatics



Covers how work, force, and energy are applied to principles of pneumatics. Shows operating principles of reciprocating, positive displacement, rotary, and dynamic air compressors. Covers primary and secondary air treatment. Includes valves, logic devices, cylinders, and air motors.



Pneumatic Troubleshooting



Covers pneumatic systems, schematic symbols and diagrams, installing system components, planned maintenance, system diagnosis, and troubleshooting. Includes maintenance of air compressors, control valves, air motors, electrical components, and hybrid systems.





The Refrigeration Cycle



Introduces the basic concepts needed for an understanding of refrigeration. Traces the basic refrigeration cycle. Explains the concepts of heat, temperature, humidity, dewpoint, enthalpy, and simple psychrometrics. Concludes with a lesson on the tools and instruments needed for refrigeration servicing and safe work practices.



Refrigerants and Refrigerant Oils



Covers the physical properties of refrigerants, including pressure-temperature relationships. Discusses various kinds of refrigerant and their safe handling. Examines the effects of refrigerants on the atmosphere and related EPA requirements. Discusses filters, driers, leak detection equipment, gauge manifold set. Explains system charging, evacuation and dehydration, refrigerant recovery/recycling, and oil maintenance and servicing.






Explains the function of the compressor in a refrigeration system. Introduces information on the construction and use of reciprocating, rotary, helical, scroll, and centrifugal compressors. Covers compressor motors, control, and protection. Concludes with a lesson on preventive maintenance for compressors as well as troubleshooting and repair.



Evaporators and Metering Devices



Explains the function and construction of evaporators. Covers direct-expansion, dry-expansion, and flooded evaporators, as well as systems using multiple evaporators. Discusses ways to boost evaporator performance. Explains evaporator defrosting, maintenance, and troubleshooting. Describes the function, operation, and maintenance of various metering devices, including hand-operated, automatic, thermostatic, thermal-electric devices.



Condensers and Cooling Towers



Covers the function, construction, and operation of both air- and water-cooled condensers and related devices. Discusses cooling towers and spray ponds, including maintenance and troubleshooting. Includes a lesson on evaporative condensers. Concludes with a discussion of water-related problems and how to solve them.






Examines piping system materials and sizing. Includes coverage of codes, valves and fittings, and the cutting and joining of piping and tubing. Explains the function and unique requirements of the discharge line, liquid line, and suction line. Concludes with a lesson on piping system maintenance, including handling dirt and scale, expansion, vibration, corrosion, and leaks.



Control Systems



Introduces the need for control, control methods, and system basics. Includes information on self-powered, pneumatic, hydraulic, electric, and electronic systems. Covers various sensors and controlled devices. Covers the basics of two-position, floating, and proportional control systems and their maintenance and troubleshooting. Discusses the various processes requiring control in a refrigeration or air-conditioning system.



Air-Handling Systems



Begins with coverage of airflow basics, including how air moves, types of airflow, and pressure relationships. Compares and contrasts various types of fans and fan motors. Examines types of ducts, fittings, connections, insulation, and terminal devices. Covers various methods of cleaning and filtering air, as well as balancing and troubleshooting the air-handling system. Concludes with a lesson on indoor air quality and sick building syndrome.



System Troubleshooting



Discusses the keys to effective troubleshooting and emphasizes the importance of safety. Details a step-by-step procedure to use when troubleshooting. Covers the use of a troubleshooting flowchart. Examines three sample problems, leading the trainee through the steps necessary to locate the problem in each example.



Absorption Chillers



Covers the basic principles of absorption refrigeration as compared to mechanical refrigeration. Introduces absorption terminology and common absorption fluid pairs. Examines water/lithium bromide systems, ammonia/water systems, and evolving systems. Concludes with a discussion of chiller selection factors, cost of operation, and absorption system applications.



Heat Pumps



Introduces the heat pump concept and related terminology. Covers water-to-water, water-to-air, ground-to-air, air-to-air, solar-assisted, geothermal, dual-fuel, and split systems, as well as packaged units. Defines balance points, coefficient of performance, energy efficiency ratio, and degree days. Covers components, controls, installation, checkout, and startup.



Heating System Basics



Covers fundamental information on all types of heating systems. Begins with the concept of heat energy, heat transfer, and temperature scales. Examines factors affecting human comfort. Introduces all types of heating equipment and its operation. Includes a Lesson on combustion and thermal efficiency. Concludes with a lesson on duct systems.



Heating System Equipment



Covers the hardware associated with heating systems, including gas and oil furnaces, electric systems, solid-fuel and hydronic systems, and finally some alternative systems–solar heating, heat pumps, and fuel cells. Includes a discussion of furnace performance criteria, return air systems, and the importance of filters.





Ammonia Refrigeration Basics



Covers all aspects of using ammonia as a refrigerant. Describes both single-stage and two-stage ammonia systems. Explains the importance of accumulators and intercoolers in ammonia refrigeration. Concludes with coverage of liquid recirculation system operation.



Positive-Displacement Compressors



Begins with coverage of reciprocating compressors-their design, lubrication, efficiency, and application. Covers rotary vane compressor operation and limitations. Details screw compressors and the operation of related drive, lubrication, capacity control, and safety systems. Discusses oils and the importance of system lubrication.



Evaporators, Condensers, and Controls



Covers gravity feed, overfeed, dump trap, CPR, and DX supply systems. Describes evaporator and evaporative condenser design, selection, and operation. Discusses various defrost systems-hot gas, electric, water, and glycol spray. Examines stop, shutoff, relief, check, solenoid, expansion, pressure-regulating, and float valves.



Purging, Piping and Safety



Explains the effects of noncondensables on an ammonia system and the importance of their removal. Covers a wide range of piping considerations-sizing, flow rate, pressure drop, and others. Concludes with a thorough coverage of safety codes and programs, including ANSI/ASHRAE, IIAR, OSHA, and EPA information.





Introduction to Carpentry



Gives the new trainee a grasp of the basics of carpentry. Aims to familiarize persons who have had no carpentry experience with the tools and materials of the trade. Covers specifications, estimating procedures, codes, and how to read prints and plans.



Constructing the Building Shell



Covers basic building techniques common to most structures, including methods of laying foundations, framing, covering walls, and roofs.



Finishing the Building Interior



Covers constructing stairways, installing doors, and finishing procedures. Emphasizes interior walls, ceilings, and floors.



Structural Painting



Covers the techniques of selecting and applying paints and coatings to buildings, inside and out. Describes the composition of paints and other coatings, and how to use brushes, rollers, spray guns, and other tools of application. Also describes how to prepare new and existing surfaces for coating, and explains the easiest, most successful techniques of application.



Flat Roof Maintenance



Introduces roofing, including flat roof systems and various types of decks. Examines insulating and water-proofing materials, and techniques of application. Discusses roofing damage, how to repair roofs, and how to make a proper roof inspection. Explains types of preventive maintenance, how to plan preventive maintenance, and how to select the proper materials to use.



Plumbing Systems Maintenance



Covers maintaining plumbing systems in a factory, plant, or other industrial or commercial site. Describes the structure and function of on-site plumbing systems (water supply, sanitary waste, and storm water), and explains how the major fixtures in these systems work. Tells how to take care of common plumbing problems.



Locks and Key Systems



Covers basic lock types: mortise, auxiliary or rim, tubular bolt, key-in-know, narrow stile, and unit lock. Explains how they operate, how to install, maintain, and adjust them. Also describes key control, master key systems, panic bars, and other accessories for building security.



Landscaping Maintenance



Covers the major features of landscaping maintenance, from the basics of how plants develop to recognizing diseases and parasites. Details the selection and care of trees, ground covers, flowers, and grasses.





Cleaning Chemicals



Covers the safe use of cleaning chemicals, including the OSHA Hazard Communication standard. Covers the basic chemistry of cleaning chemicals, then explains the correct use of detergents, soaps, solvents, disinfectants, and other cleaning chemicals. Explains how chemicals are packaged, labeled, mixed, and applied in order to make working with chemicals safer and the trainee more efficient.



Floors and Floor Care Equipment



Covers many different kinds of floors and flooring materials in use in many locations. Covers a variety of powered floor care equipment, explaining how to operate each device safely and efficiently. Explains how and why to use floor machines and vacuum cleaners and their various attachments. Also covers the use and maintenance of autoscrubbers, powered sweepers, pressure washers, and sanders.



Maintaining Floors and Other Surfaces



Covers the tasks involved in the daily, routine maintenance of floors. Lists kinds of floor coatings and the uses of each. Explains periodic floor care tasks step-by-step, and tells trainees which particular methods to use on the various floors and floor coverings they will work with in their buildings. Covers floor care problems trainees are likely to encounter. Concludes with a lesson on the cleaning of walls, windows, furniture, and other above-the-floor surfaces.



Rest Room Care



Covers the fundamentals of rest room design and construction and the elements of routine rest room cleaning. Covers the specifics of cleaning rest room plumbing fixtures. Describes the periodic tasks required to keep rest rooms in good condition. Finally introduces the trainee to the topic of disinfection, its importance in rest rooms, and methods of performing this task safely.



Carpet and Upholstery Care



Covers the many kinds of carpet in use today. Explains the importance of preventive maintenance. Gives step-by-step explanations of the various carpet-cleaning methods available, explaining which is best to use on different types of carpet. Covers stretching, bleeding, insect attack, and many other carpet problems, and suggests remedies. Concludes with a lesson on upholstery fabrics and their care.


ELECTRONICS (Series 250)






Covers the theory behind semiconductor operation. Describes the characteristics and operation of various diodes and transistors. Stresses the importance of proper environmental conditions and explains how to minimize electrostatic discharge (ESD) and radio frequency interference (RFI). Discusses printed circuit board (PCB) and integrated circuit (IC) technology, including connection and replacement methods. Identifies kinds of semiconductor packages. Explains how to interpret manufacturers' spec sheets and how to analyze circuit performance by Q points and characteristics.



Power Supplies



Covers the four basic kinds of power supply conversions. Explains how to work with nonchemical cells as well as primary and secondary cells of various materials. Describes in detail the functions and operation of several kinds of rectifiers, filters, and voltage regulators and explains how they work together as power conditioners. Discusses basic tools, test devices, and procedures for troubleshooting to solve the greatest number of problems in the least amount of time.






Covers the effects of gain, bandwidth, and distortion on amplifier performance. Compares linear and nonlinear (switching) amplifiers. Explains how to use transistor curves to analyze amplifier operation in terms of operating regions, load lines, operating (Q) points, and biasing. Discusses impedance matching and compares capacitive, transformer, and direct-coupled amplifiers. Describes many ways op amps are used today, including integrators and comparators. Provides specific methods for troubleshooting common amplifier problems.






Covers how oscillation is started and maintained. Compares LC (tuned), RC (phase-shift), and crystal oscillators. Compares sine-wave oscillators and square-wave switching circuits. Discusses monostable, astable, and bistable flip-flop operation in detail and shows expected waveforms. Explains how logic clocks are generated and conditioned. Discusses Schmitt trigger circuits, frequency dividers, and ripple counters, as well as propagation delays and glitches. Describes the operation of low-pass, high-pass, band-pass, and band-reject filters, including differentiators and integrators. Describes the equipment and procedures for troubleshooting oscillator components and circuits.



Digital Logic Systems



Covers the comparison of analog and digital switching circuits. Explains Boolean logic functions. Describes TTL and CMOS logic, as well as IC logic devices. Explains how flip-flops, clock circuits, counters, multiplexers, and memory circuits work. Describes the sections and interfaces in functional logic systems, including microprocessors. Describes proper methods for detection and correction of common fault potentials.





Energy Conservation Basics



Covers energy sources and the history of energy usage. Examines alternative energy sources and their feasibility. Identifies current energy usage patterns and places where energy can be conserved. Explains how to recognize energy waste, and includes sample corrective actions. Explains how to conduct an energy survey.



Energy Losses in Buildings



Covers physical laws of heat transfer and how they apply to building heat losses. Discusses effects of sun, wind, and shade on energy consumption in buildings. Examines characteristics of different types of walls, roofs, windows, and flooring. Demonstrates how different forms of insulation can improve thermal resistance. Gives sample applications of energy conservation measures, illustrating how to determine cost and payback period.



Heating/Cooling System Efficiency



Covers the measurement of various environmental factors and their effect on human comfort. Introduces the concept of zones. Covers ventilation requirements and savings possible by reducing airflow. Examines energy waste vs. conservation measures relating to furnaces, boilers, air conditioners, and refrigeration equipment.



Mechanical Energy Conservation



Covers the causes and effects of friction and the importance of lubrication. Includes a discussion of efficient operation of materials handling systems, elevators, and escalators. Examines ways to conserve energy by reducing vibration. Explains the importance of good maintenance of pumps, blowers, and compressors. Includes a lesson on vehicle efficiency, with emphasis on tuneups, lubrication, and other energy-saving maintenance practices.



Electrical Energy Conservation



Covers electrical energy consumers in typical commercial and industrial facilities. Investigates utility rate structures and relates cost to load management. Examines power factors, including how they are calculated and how they affect energy usage. Shows methods of conducting lighting surveys and how lighting fixture and lamp selection can impact electricity costs.





Force and Motion



Covers fundamentals of force and motion, showing how an engineer thinks about these concepts. Demonstrates how mathematical and graphical representations can help clarify our thinking about mechanical force and motion.





Chemical Hazards



Covers OSHA'S Hazard Communication Standard. Discusses the physical and health hazards presented by dangerous chemicals. Explains the information contained in a Material Safety Data Sheet (MSDS).





Machine Shop Practice



Covers the principles of machining, measurement, tool grinding, and machine shop safety. Discusses the properties of metals, how to lay out and set up a job, how to use measuring devices such as the micrometer and vernier caliper, and how to read working drawings. Explains how to grind single-and multi-point tools.



Machine Shop Turning Operations



Covers the major types of lathes and their attachments, safety, maintenance, job preparation, and basic lathe operations. Discusses all facets of drilling and boring, types of drills and drill presses, milling machines, and job bores. Explains reaming and reamer terms. Covers threads and threading.



Machine Shop Shaping Operations



Covers types of milling machines and milling operations. Covers spindles, arbors, feed rates, and safety precautions. Discusses shaper and planer operations-setup, maintenance, and safety procedures. Also introduces grinding, power sawing, and gear cutting operations.



Machine Shop Job Analysis



Covers types of jobs likely to be encountered by the maintenance machinist, and describes how the machinist decides which machine(s) to use for particular operations. Shows how to analyze the entire job before selecting the most efficient sequence of machining operations. Builds on Courses 315, 316, 317, and is a prerequisite for the "hands-on" projects in the courses that follow.



Lathe-Turning Work Between Centers



Takes the trainee through a series of operations on the lathe to make a student project (a plug gauge). Covers lathe setup, rough turning procedures, finish turning, and chamfering. Next covers shouldering, knurling, and notching operations. Finishes with external thread cutting and marker tapers.



Lathe-Machining Work in a Chuck



A sequential follow-up to Course 324 on lathe operation, covers chuck installation, boring and counterboring operations, thread cutting, and taper boring. Continues into special lathe operations that use faceplates, angle plates, and boring bars. Provides several real "hands-on" projects.



Basic Milling Procedures



Covers the setup and use of the horizontal milling machine, and describes the functions of basic cutters and attachments. Uses "hands-on" projects so trainees actually gain experience on the milling machine. Includes a work-holding fixture project that can have practical value in the shop when finished.



Indexed Milling Procedures



Covers the use of the dividing head. Covers plain, differential, and angular indexing. Explains the use of the dividing head for milling hexagons. Proceeds to the cutting of spur gears, helical gears, and cams.



Multiple-Machine Procedures



Previous courses have dealt largely with the operation of two major machine tools, the lathe and the milling machine. This course picks up some of the other machines found in a machine shop, some of which may be used infrequently, but which nevertheless require specific skills to operate. In most cases, simple projects are described to give trainees experience working with these machines.




Bulk-Handling Conveyors



Covers belt conveyors that carry coal, sand, gravel, grain and other loose materials. Acquaints the trainee with the terminology, basic structure, and operation of these systems. Includes detailed coverage of belts, belt cleaners, idlers, and feed/discharge devices, as well as an explanation of how to install, maintain, replace, and troubleshoot these components.





Mechanical Drive Maintenance



Covers alignment, particularly coupling alignment. Includes installation and maintenance of mechanical drives, from chain drives to enclosed gear drives.



Mechanical and Fluid Drive Systems



Covers further details of drive maintenance, including brakes, clutches, and adjustable-speed drives. Also covers maintenance and troubleshooting of fluid drives and package drive systems.



Bearings and Shaft Seal Maintenance



Covers plain bearings, their parts, dimensions, functions, and relining techniques. Continues with installation and replacement of antifriction bearings. Also covers linear motion bearings and shaft seals.



Pump Installation and Maintenance



Covers basic pumping concepts. Describes required maintenance of packing and seals. Covers maintenance and overhaul of centrifugal pumps. Concludes with maintenance of rotary pumps.



Maintenance Pipefitting



Covers components and terminology used in piping systems. Also covers terminology, measurement, and maintenance of threaded, welded, and plastic piping systems. Explains the use of pipefitting accessories-supports, traps, filters and strainers, and expansion joints.



Tubing and Hose System Maintenance



Covers tubing specifications, materials, and fittings. Explains procedures used for handling, bending, cutting, and installing tubing. Gives basics of tubing in a hydraulic system. Describes hose systems and their functions. Concludes with gaskets, sealants, and adhesives.



Valve Maintenance and Piping System Protection



Covers maintenance and operation of gate, globe, ball, plug, check, and special-purpose valves. Details actuators and various accessories. Explains valve selection based on application. Describes methods of protecting piping systems.





Introduction to Packaging



Covers the job of packaging mechanic. Provides detail on major types of packaging machinery. Covers various mechanical drives, couplings, motors, brakes, variable speed drives, clutches, electrical controls, motor starters, event sequencing controls, time delays, and relays. Includes packaging specifics: types of materials, methods of filling, methods of sealing, weights, and volumetric measurements.



Packaging Machinery



Covers operating and servicing various types of packaging machinery. Describes different types of liquid filling machines. Covers positive displacement fillers, filling, and sealing machines, as well as volumetric filling machines and blister packaging machines.



Casing Machinery



Covers operating characteristics and service techniques of accessory or auxiliary machines used with packaging lines. Describes general operating characteristics of labeling equipment, uncasing, unscrambling, and cleaning machines, gluing equipment and adhesives, wrapping machines, tying, strapping, and stitching machines, and shrink wrapping devices.





How Power Plants Work



Covers the basic steam generation system, how thermal energy is converted into electrical energy, components of the system, and design features for gaining thermal efficiency. Includes handling of water, fuel, and wastes, and the operating features of a power plant.



Generating Steam in the Power Plant



Covers energy principles and boiler maintenance. Explains coal, oil, and natural gas combustion, and how to conserve energy through improved combustion control.



Using Steam in the Power Plant



Covers how to conserve energy in turbines, auxiliaries, electric power generation, and air conditioning systems.



Waste to Energy Fundamentals



Covers fundamentals of waste combustion-characteristics and handling of MSW fuel, furnace designs, waste combustion, and plant operations.





Introduction to Process Control



Covers the function of basic devices for measuring and controlling different kinds of variables in process control. Introduces closed-loop control and PID functions. Introduces analog and digital devices and programmable logic controllers (PLCs). ISA and SAMA instrumentation symbols and interpretation and use of process diagrams are covered.  



Pressure Measurement



Covers units of pressure and discusses Boyle's and Charles' laws to explain relationships among pressure, volume, and temperature. Describes sensor operation of manometers, bourdon tubes, diaphragms, and bellows. Explains the operation of potentiometric, capacitive, reluctive, servo, strain-gauge, and piezoelectric transducers. Describes devices used in low-pressure control. Discusses proper and safe methods for installing and servicing pressure instruments.



Force, Weight, Motion Measurement



Covers force, stress, and strain and explains the operation of strain-gauge systems. Relates weight to mass and scales to balances. Explains the operation of load-cell scales. Describes belt-scale, nuclear-scale, and weigh feeder operation. Covers position measurements by means of proximity detection, air gauging, LVDT gauges, synchros, code disks, and other devices. Explains machine tool control and accelerometer operation. Describes the measurement of angular velocity and acceleration, vibration detection, and machinery balancing.



Flow Measurement



Covers principles of fluid flow and how primary devices affect fluid flow. Describes flow measurement using several kinds of secondary devices. Discusses rotameters and other variable-area instruments. Explains how weirs, flumes, and other arrangements measure open-channel flow. Compares many kinds of positive-displacement meters and explains the operation of several kinds of turbine and magnetic flowmeters. Describes less-common flowmeters (including vortex-precession, mass flow, and ultrasonic devices) and instruments that meter the flow of solids. Provides guidelines for safe installation and maintenance of flow devices.



Level Measurement



Covers principles governing various methods of measuring level. Explains operation of conductive, capacitive, resistive, ultrasonic, and photoelectric devices. Compares the operation of several kinds of pressure-head instruments. Explains the measurement of solids by ultrasonic, microwave, radiation, and other methods. Discusses several special-application devices for both continuous and point level measurement.



Temperature Measurement



Covers units in thermal measurement and operation of RTDs (and wheatstone bridges), thermistors, and thermocouples and thermometers. Includes principles of pyrometry and operation of narrowband, broadband, and bandpass pyrometers. Discusses calibration standards, typical calibrating methods, and instrument testing.



Analytical Instrumentation



Covers principles, installation, calibration, and maintenance of conductivity probes, and methods of stack gas monitoring. Includes how to install, calibrate, and maintain pH and ORP measurement instruments and operation, installation, calibration, and maintenance of several optical analyzers. Discusses principles and safe practices governing sensors used in measuring oxygen, carbon monoxide, carbon dioxide, and other products of combustion. Concludes with operation, calibration, and system components in liquid and gas chromatography.



Final Control Elements



Covers how elements in a closed-loop system affect final control element. Describes components in final control subsystems. Discusses operations of solenoids, motors, relay systems, and PLCs. Explains pneumatic actuators and positioners. Describes mechanical advantage in several hydraulic control systems. Compares construction, characteristics, and applications of eight control valves. Traces operation of each element in typical feedwater, turbine, and robotic control systems.



Safety, Calibration, and Testing Procedures



Covers the responsibilities of employer, employee, and regulatory agencies in maintaining safety. Discusses ways of identifying and handling chemical, electrical, biological, radiation, and mechanical hazards. Discusses importance of maintenance (including calibration) and proper record keeping. Describes use of common electrical and electronic test instruments. Offers guidelines for handling heavy equipment, decontaminating and servicing pneumatic and hydraulic equipment, and troubleshooting.





Working with Controllers



Covers the purposes and kinds of controllers and their relationship to other components in process control systems. Explains the concepts of current-, position-, and time-proportioning control. Compares the operation of several kinds of controllers. Describes the operation of proportional, integral, and derivative modes, and discusses tuning procedures for each. Discusses cascade, feedforward, ratio, and auctioneering control systems as well as other operations. Describes ways to eliminate or reduce controller problems.



How Control Loops Operate



Covers definition of control loop terms and characteristics. Includes specific examples of operation of control loops of many kinds. Discusses proportional, integral, and derivative modes in detail. Describes advanced control methods by means of four strategies with specific examples. Examines the effects of loop dynamics on system stability.



Data Transmission



Covers mechanical, hydraulic, pneumatic, and telemetric data transmission methods. Discusses indicators, other devices, and methods used for electrical/electronic data transmission in detail. Compares methods and standards for parallel and serial digital data transmission. Describes optical isolation and the operation of optical data transmission systems in detail. Provides specific methods for preventing common kinds of data transmission interference.



Computers in Process Control



Covers the evolution of today's process control computer systems. Compares smart components to older conventional system devices. Covers the architecture (hardware and software), configuration, and operation of distributed control systems in depth (two entire lessons) by using as an example a typical DCS controlling an ice cream plant. Defines common terms used in today's integrated plant and discusses the integration of discrete and continuous processes with plant business functions.





Programmable Logic Controllers



Prepares technicians to take full advantage of vendor training on specific equipment. Covers the basic operating principles of all PLCs, their inputs and outputs, programming, maintenance, and networking.





Industrial Rigging Principles and Practices



Covers techniques and safeguards in the use of rope, chain, hoists, and scaffolding when moving heavy plant equipment and maintaining plant utilities.



Equipment Installation



Covers installation procedures for large plant equipment. Considers factors affecting proper installation in detail, from preparatory relocation of underground piping and wiring, through equipment anchoring, aligning, and test running.


ROBOTICS (Series 500)



Introduction to Robotics



Covers the background for a detailed study of robot maintenance. Introduces the trainee to the basics of robotics, using clear, easy-to-follow language to take the mystery out of this growing technology.





Introduction to Water Technology



Covers the nature, use, and properties of water. It traces the history of water treatment methods from ancient times to today's sophisticated systems. The effects of chemical and biological factors on the purity of water are explained.



Wastewater Treatment Processes



Covers the various stages of wastewater treatment. Goes into detail on the removal of solids, then explains the use of chemical and biological processes for water purification. Covers the treatment and disposal of the extracted solids.



Maintaining Wastewater Equipment



We rely on modern methods of water and wastewater treatment to help prevent disease and to preserve our environment. This series concentrates on water treatment in municipal plants. Therefore, it is most useful to those who are interested in water treatment on the community level.


WELDING (Series 420)



Blueprint Reading for Welders



Covers basic shop math and measurement skills. Explains how to read, use, and make blueprints. Discusses various welds, weld joints, and weld symbols. Explains advanced shop math and measurement skills.



Welding Principles



Covers fundamentals of welding. Discusses welding safety considerations and precautions. Covers both oxyfuel and arc welding equipment. Describes welding techniques and symbols. Discusses ways to avoid weld faults.



Oxyfuel Operations



Covers the welding of ferrous and nonferrous metals. Describes oxygen cutting as well as brazing and soldering. Discusses surfacing techniques.



Arc Welding Operations



Covers shielded metal arc welding, selecting electrodes for SMAW, gas metal and tungsten arc welding, preheating, reheating, welding ferrous and nonferrous metals, pipe welding, hard facing, and rebuilding.





Maintenance Organization



Covers the basic types of maintenance organizations. Discusses cost-saving concepts of using work order systems. Explains how to develop and use information sources to implement maintenance management. Shows how to apply work standards and planning procedures to simplify a supervisor’s job. Introduces the use of computers for first-line supervisors.



Implementing Preventive Maintenance



Covers what PM is and why it is necessary. Develops procedures for setting up a practical PM program, and describes effects of PM on scheduled and unscheduled work. Explains the requirements and advantages of the program as it applies to maintenance management. Provides information on the relationship of PM to production and quality control.



Controlling Maintenance Resources



Covers methods of using maintenance resources for greatest efficiency, and tells how to implement the techniques effectively. Explains what workload is and how to measure it. Provides a thorough investigation into the control of labor, parts, and materials—both in the field and in the shop. Examines the budget process and how to control costs through budgeting.



Improving Performance in Maintenance



Covers instructions to first-line supervisor in the strategies involved in improving performances, and presents proven methods for increasing maintenance productivity. Develops ways of evaluating training effectiveness and the management of time. Describes the information necessary to stimulate improvement in all facets of the maintenance program.



Effective Communication for Supervisors



Covers how to use verbal and written communication tools, including the importance of listening. Explains how to motivate personnel through effective communication. Discusses how to organize written communication, best utilizing the elements of writing—parts of speech, phrases, clauses, sentences, structure, punctuation, and syntax. Gives examples of business writing used for reporting progress and motivating employees.



Employee Relations



Defines the supervisor’s job in terms of maintenance planning, operations, and employee interaction. Demonstrates how good leadership requires administering discipline fairly, recognizing employee needs, and preventing employee strife. Discusses the basic information supervisors need in handling grievances and union disputes.



Managing a Training Program



Covers analysis of training needs. Describes various kinds of training and lists important steps in administering training. Compares group management techniques to self-study. Discusses the training environment. Examines how to keep training records and how to evaluate training results.





Industrial Hydraulics



This course begins by introducing the physics of applied hydraulics, hydraulic components, and applications. It explains how a simple system functions, including symbols and basic formulas. It concludes with the subject of proportional control, including types of proportional-control valves.



Mobile Hydraulics



This course introduces the physics of applied hydraulics, hydraulic components, and applications. It explains how a simple system functions, including symbols and basic formulas. It discusses the components in the hydrostatic drive transmission and examines open- versus closed-center circuits and the functional description of forward, neutral, and reverse drive circuits. It concludes with the subject of proportional control, including types of proportional-control valves.






This course introduces the basic physics of energy, work, and power as related to pneumatics. It explains gas laws, flow, pressure, and the basic components of a pneumatic system. It includes air preparation and conditioning, calculation of force and torque, and graphic symbols. It emphasizes the importance of schematics in technical communication related to pneumatic circuits.






This course introduces the physics of energy, work, and power in relation to mechanics. It introduces simple machines and their application. It describes linear actuators, mechanical clutches and brakes, anti-friction bearings, gears and gear terminology, belt and chain drives, and mechanical couplings, including their principles of operation and applications.



Introduction to Electricity



This course explains the fundamentals of electricity, including voltage, current, magnetism, and Ohm’s Law. It introduces inductance, capacitance, and resistance, and discusses the basics of dc circuits, including series, parallel, and series parallel. It continues with the fundamental components that control circuit current and voltage, their applications, and their associated symbols.



Mobile Electricity



This course explains the fundamentals of electricity, including voltage, current, magnetism, and Ohm’s Law. It introduces inductance, capacitance, and resistance, and discusses the basics of dc circuits, including series, parallel, and series parallel. It continues with the fundamental components that control circuit current and voltage, their applications, and their associated symbols. It explains how a battery stores and dispenses electrical power and how an alternator generates electricity and concludes with the starting systems and remote start/stop features associated with many vehicles.






This course introduces PLCs and related hardware, basic PLC functions, and programming. It covers number systems used with PLCs, integers, floating-point numbers, and the handling of negative numbers. It provides information on I/O accessing, program storage, types of data, fault detection, and how the PLC coordinates these functions. It includes timers and typical PLC timing tasks, as well as simple ladder programs.



AC-DC Drives



This course covers electromechanical systems, their terminology, and how the components function together. It examines the magnetic and electromagnetic properties of dc motor components, motor operation and classification, the creation of mechanical energy by ac motors and how electromagnetism and induction produce rotation. It discusses methods for stopping motors, the components of a brushless servo motor, and speed torque curves. It concludes with coverage of output power, the control section, and I/O servo drives.



Multimeter Basics



This course demonstrates the differences between analog and digital testers and their proper usage. It also covers the fundamentals of using electrical testers as well as the testing of circuits and circuit components.