Lesson Plan for NMC XX MAINTENANCE COURSE FOR ENGINEERS

Engine Maintenance for Junior Engrs. Aims to Improved Skills and Competency of Engineers Personnel in Performing Engine Maintenance Job

Remarks
Page (Video/
Contents Details Reference Instructio Time Local (mins.)
from n Manual/ (mins.)
Handout STARS/etc.
)
1ST DAY
Opening and Introduction 1st Day ask trainee to change
Self introduction - Trainees and instructors; 10 09:00~09:10 to working clothes
Name, rank, job experience (NYK, type of ships), etc.
[View NYK
Objectives Group Values
Video
1. Explain the objectives of the course. Explain NYK Group Values [View NYK Group Values Video presented presented by 15 09:10~09:25
by Chairman Koji Miyahara] Chairman Koji
Miyahara]
Course Schedule
10 09:25~09:35
Explain the Course schedule
1 Management of Worksite and Safety of Works 1
Guideline for Safe Practices in Worksite 1
.1 Tool Box meeting 1
15 09:35~09:50
1. Discuss the importance of toolbox meeting. 1
2. Discuss the procedure of conducting a toolbox meeting. 2
2. Job Hazard Assessment 2
1. Discuss the definition and importance of JHA. 2
2. Discuss the benefits of having a JHA. 3 30 09:50~10:20

3. Discuss the potential hazard and preventive measures. 3

4. Kiken Yochi Training 5
Tea Time 15 10:20 ~ 10:35
3. Near-Miss (Dangerous Events and Irregular Looks DEVIL) Unsafe Acts/Unsafe Condition 8
1. Explain the Importance of nearmiss reporting. 8
30 10:35~11:05
2. Discuss the nearmisses concerned during maintenance. 9
3. Discuss the procedure on how to report a nearmiss. 10
4. Discuss matters needed to be reported to chief engineer 11 10 11:05 ~ 11:15

5. Personal Safety in the Engine Room 11

10 11:15 ~ 11:25
1. Enumerate and discuss some of the PPE's used onboard. 12
6. Proper Use of Tools and Measuring Instruments that are Commonly used in Engine Room 14 5 11:25~11:30

1. Discuss tools that are commonly used in the E/R. (Adjustable wrench to Chain Hoist) 15
-Adjustable Wrench 15 Discuss only 0.69 Brief Discussion only
-Single open ended spanners/ Double open end spanners 15 Discuss only 0.69 and Make it fast during discussion
-Straight Pipe Wrench 16 Discuss only 0.69
-Solid Steel Bar Wrench 16 Discuss only 0.69
-Spud Wrench 16 Discuss only 0.69
-Single End Angle Wrench 16 Discuss only 0.69
 -Hook Spanner Wrench 17 Discuss only 0.69
-Socket Wrench 17 Discuss only 0.69
-Hexagon Wrench (Allen Key) 17 Discuss only 0.69
-T- Wrench 17 Discuss only 0.69
-Flat Nose Pliers 18 Discuss only 0.69
-Combination Pliers 18 Discuss only 0.69
-Side- cutting Pliers 18 Discuss only 0.69
-Water Pump Pliers / 18 Discuss only 0.69
-Snap Ring Plier 19 Discuss only 0.69
-Hand Snip 19 Discuss only 0.69 11:30~11:50

-Tongs 19 Discuss only 0.69

-Hammer/ Lead Hammer 19 Discuss only 0.69
-Ball Peen Hammer 20 Discuss only 0.69
-Cold Chisel 20 Discuss only 0.69
-Hand taps and Dies 20 Discuss only 0.69
-Gasket Cutter 21 Discuss only 0.69
-Machinist Files 21 Discuss only 0.69
-Gear and Wheel Puller 21 Discuss only 0.69
-Pipe Cutter 21 Discuss only 0.69
-Bench Vice 22 Discuss only 0.69
-C-type screw clamp 22 Discuss only 0.69
-Screw Drivers 22 Discuss only 0.69
-Chain Hoist 23 Discuss only 0.69
2. Discuss the proper usage of surface plate 24 Discuss only 5 11:50 ~ 11:55

3. Discuss how to use scriber 24 Discuss only 5 11:55 ~ 12:00

Lunch break 12:00 ~ 13:00

4. Discuss/demonstrate the importance of test hammer in checking the tightness of bolts. 24 2

5. Demonstrate how to use feeler gauge 24 2
6. Demonstrate how to use dial indicator 25 2
13:00 ~ 13:20
7. Discuss the proper use and maintenance of Torque Wrench / Measurement Conversion 25-26 2
8. Enumerate and discuss the different tools and measuring instruments and their applications 26 10
9. Discuss the solution in converting units of measurement (ex. Unit of force, pressure and etc.) 27 2
17. Demonstrate how to use outside and inside micrometer 28-30 5 13:20 ~ 13:25
18. Demonstrate how to read measurement of Micrometer 28-30 20 13:25 ~ 13:45
19 . Demonstrate how to use and read measurement of vernier caliper 30-31 20 13:45 ~ 14:05

7. Discuss the proper use of Tools 31

5 14:05 ~ 14:10
8. Discuss the proper care of basic tools 32
9. Proper Storage and Correct Location of Tools Needed During Emergency Situation 33
1. Discuss the proper use and storage of hand tools 33 2 14:10 ~ 14:12

1. Discuss the importance of proper storage of tools in the engine room. 33 2 14:12 ~ 14:14

2. Discuss the correct location and proper storage of tools when not in use. 33 2 14:14 ~ 14:16

3. Enumerate and discuss the things or places to avoid when storing the tools. 33 2 14:16 ~ 14:18
 4. Enumerate and discuss the preventive measures when storing the tools to avoid accident, 33 2 14:18 ~ 14:20

tool damage or machinery damage.

10 General Works in the Engine Room 34
1.Discuss the application of different types of lapping and grinding compounds 34 5 14:20~14:25

2. Demonstrate the procedures on how to detect crack and flaw of bearings and other parts of D/G. 35 5 14:25 ~ 14:30

3. Demostrate the proper checking of screw thread condition. 38 3 14:30 ~ 14:33

4. Demonstrate the proper way of using thread lubricant. 38 3 14:33 ~ 14:36

5. Enumerate and discuss the different types of washer. 39 3 14:36 ~ 14:39

6. Discuss the application and use of each type of washer. 39 3 14:39 ~ 14:42

7. Demonstrate how to adjust V-belt 40 3 14:42 ~ 14:45

8. Discuss the proper use of tap and dies 41 3 14:45 ~ 14:48

9. Table for screw nominal size and diameters 41 4 14:48 ~ 14:52

10. Differentiate / Demonstrate tag in and tag-out devices 43 4 14:52 ~ 14:56

11. Differentiate / Demonstrate lock-out and lock in devices 43 4 14:56 ~ 15:00

Tea Time 15 15:00 ~ 15:15

11. Recent Trouble Incidents 45 25 15:15 ~ 15:40

12. General Guidelines on Maintenance and Inspection 45 20 15:40 ~ 16:00

12. Discuss the procedures on tightening bolts by torque. 46 5 16:00 ~ 16:05

13. Discuss/demostrate the procedures in operating hydraulic oil jack during D/G maintenance. 47 Hands On 5 16:05 ~ 16:10 To Demo in Workshop
14. Discuss the proper way of installing O-rings of Hydraulic Jack 48 5 16:10 ~ 16:15

15. Demonstrate the use of Hydraulic jack by pulling out Hyd. Bolts of M/E Exh. Valve 48 Hands On 25 16:15 ~ 16:40 To Demo in Workshop
16. Discuss the procedures on tightening bolts by hydraulic. 48 Discuss only 5 16:40 ~ 16:45

17. Explain the difference between torque bolt tightening and hydraulic bolt tightening. 48 Discuss only 5 16:45 ~ 16:50

18. Discuss the Bolt tightening sequence by torque 49 Discuss only 5 16:50 ~ 16:55

Discuss the Activities for the next 4 days, Preparation for Hands On Exercises 5 16:55 ~ 17:00

2ND DAY
13. Maintenance of Auxiliary Machinery
Auxiliary Diesel Engine 52
Discuss, Plan, Prepare, Proper tools Needed for D/G Overhauling (Give Job Cards, Drawing Plan) 52
1. Demonstrate how to perform maintenance and inspection on a Daihatsu Diesel Engine.
> crank case (deflection) > Conn. Rod Brg. (side play check) 52-53 105 08:30 ~ 10:00

Tea Time 15 10:00 ~ 10:15

> crank case (deflection) > timing injection & Camshaft Inspection 53 45 10:15 ~ 12:00

Lunch break 12:00 ~ 13:00

> fuel injection pump Inspection > fuel valve inspection 59 60 13:00 - 14:00 While inspection of fuel pp and
> Preparation for Decarb. No. 1 Cyl Hd. > draw out cyl. Head and piston 59 60 14:00 ~ 15:00 fuel v/v Prepare to drain water for OH
Tea Time 15 15:00 ~ 15:15

> draw out cyl. Head and piston (1 Pc. Only) > piston & ring Inspection 54 105 15:15 ~ 17:00 After Drawing out Cyl hd and piston
3RD DAY Measure cyl liner wear &
> draw out cyl. Head and piston / > Mounting Back / Valve End Clearance Check 54 08:30 ~ 12:00 Inspect Spare Piston
Lunch break 12:00 ~ 13:00
 > Valve End Clearance check > Final Check and Run test 54 Hands On 60 13:00 ~ 14:00

> turbo charger Video Film Showing ( Water Washing, O/hauling, clearance check, Inspn.) 59 Video Show 30 14:00 ~ 14:30

> Turbo Charger Overhauling > Dismantling, Inspection, Clearance checking 59 30 14:30 ~ 15:00
Tea Time 15 15:00~15:15

> Turbo Charger Overhauling >Clearance checking /Assembling) 59 105 15:15 ~ 17:00

4th DAY
> Turbo Charger Overhauling >Clearance checking /Assembling) 59 90 08:30 ~ 10:00
tea Time 15 10:00 ~ 10:15

> Turbo Charger Overhauling >Clearance checking /Assembling, Test Run) 59 60 10:15 ~ 12:00
Lunch Break 12:00 ~ 13:00
14. Filters and Strainers 63
1. Explain the difference between filters and strainers. 63 2.5
2. Enumerate the standard mesh sizes of filters and strainers. 64 2.5 13:00 `~ 13:10

3. Enumerate and discuss the different types of filters. 63 5

15. Pumps Maintenance and Overhauling 65 Hands On
1. Practical Exercise of Gear Pump and Centrifugal Pump at Workshop
1. Discuss how to pull out/ install the pump coupling, bearing and impeller. 66
2. Discuss how to disassemble and reassemble the pump. 66-67
3. Point out the Check points while overhauling pumps 65 Interactive
discussion 110 13:10 ~ 15:00
2. Bearing 67 while having
Hands On
1. Discuss the correct procedure on installing the bearing. 67-68
2. Discuss the feel-over technique used to determine the estimated bearing temperature. 69
3. Discuss how to tighten and replace the pump gland packing 70-71
4. Discuss the different types of Packing and Comparison Table for Each Makers 71-74
Tea Time 15 15:00 ~ 15:15

Practical Exercise of Gear Pump and Centrifugal Pump at Workshop (Continuation) 75 Hands On
3. Pumps Type 75
1. Discuss the working principle of gear pump. 75
2. Discuss how to align the pump and its motor coupling/ Practical on workshop 75
3. Discuss the check points upon maintenance of a gear pump. 75
4. Discuss the maintenance procedure of a gear pump. 75
5. Discuss the procedure on proper connection and alignment of gear pump coupling. 75 Interactive 120 15:15 ~ 17:00
discussion
6. Discuss the working principle of screw pump. 75 while having
Hands On
7. Discuss the check points upon maintenance of a reciprocating pump. 75 Exercises
8. Discuss the tools needed during maintenace on a Reciprocating Pump. 75
9. Discuss the working principle of Centrifugal pump. 75
10. Discuss the check points upon maintenance of a centrifugal pump. 75
11. Discuss the proper tools needed during maintenance on a centrifugal pump. 75
5TH DAY
16. Air Compressor 75
 1. Discuss the tools needed during maintenance on Air compressors. 75
2. Demonstrate how to disassemble and reassemble the 1st and 2nd stage valve. 75 Hands On 90 08:30 ~10:00

3. Identify the check points upon maintenance and overhaul. 75

Tea Time 15 10:00 ~ 10:15

4. Demonstrate how to clean the inside of cylinder. 75

5. Demonstrate how to clean the cooler. 75
6. Demonstrate how to inspect the piston and piston rings. 76 105 10:15 ~ 12:00

8. Discuss the oil system and its maintenance (gear case inspection). 76
9. Demonstrate proper maintenance for compressor's unloader 76
Lunch Break 12:00 ~ 13:00

17. Auxiliary Boiler 80

1. Enumerate and Discuss the Safety Devices on a Boiler. 81 5 13:00~13:05

2. Discuss the common maintenance done on a Boiler. 81 5 13:05~13:10

3. Trouble Shooting regarding Burner Problems 87 15 13:10~13:25

4. Enumerate and Discuss the types of boiler burner (i.e. rotary cup type and pressurized type). 82 5 13:25 ~ 13:30

5. Discuss the common maintenance done on each type of boiler burner 88 5 13:30~13:35

6. Demonstrate the common maintenance done on a rotary type boiler burner. 83 15 13:35 ~ 13:50

7. Demonstrate the common maintenance done on a Ignition burner. 86 15 13:50 ~ 14:05

8. Inspection and Maintenance of Boiler Safety Valve (Includes Safety Precaution) 88 10 14:05 ~ 14:15

18. Heat Exchangers 88

1. Discuss types of heat exchangers. 88
2. Discuss the maintenance done and inspection points. 90
15 14:15 ~ 14:30
3. Discuss the chemical cleaning maintenance and check points on heat exchangers. 95
4. Discuss the Leak and Pressure test maintenance on a shell and tube type heat exchanger. 96
19. PMS requirements (Planning of Engine Maintenance and Condition) 97
1. Explain what is a Planned Maintenance System (PMS). 97 3 14:30 ~ 14:33

2. Discuss the importance of Planned Maintenance System (PMS). 97 2 14:33 ~ 14:35

3. Enumerate and discuss the minimum requirements that a PMS must contain. 98 2 14:35 ~ 14:37

4. Enumerate and discuss the additional requirements for computerized PMS. 98 2 14:37 ~ 14:39

5. Discuss the procedures on how to handle unscheduled maintenance, relating it to PMS. 98 2 14:39 ~ 14:41

6. Demonstrate and discuss the use and importance of filling up an engine room failure log book. 99 4 14:41 ~ 14:45

Tea Time 15 14:45 ~ 15:00

20. Understanding of Piping Diagram 99

1. Identify the different symbols used in piping diagram (in accordance with ISO) 100
2. Differentiate types of valves and its application 102
3. Identify the proper valve needed for specific application 102 30 15:00 ~ 15:30

4. Trace-up piping diagram of different system 101

5. How to Face Up Valve 108
Review Summary of Lesson /Famous Quotation( Inspiring Final Instruction to Trainees) 30 15:30 ~ 16:00

ASSESSMENT and EVALUATION 60 16:00~17:00