Skip to main content

Power Generation Maintenance Mechanic

Overview

This rigorous four-level Power Generation Maintenance Mechanic curriculum prepares learners for a career in this field.

It covers concepts maintenance electricians need to test, diagnose and repair power generation plant equipment. The curriculum includes coverage of gaskets and packing, vibration and balancing, and fuel preparation and delivery equipment coverage. Learners are also introduced to reading plant construction drawings, using test instruments, and valve installation and shielded metal arc welding.

Craft Snapshot

Journey Level
Assessment Available
PUBLISHED
2010, 1st Edition
NCCERconnect Deliver instruction using our pre-loaded content and course management tools, streamline training, and track results through the online gradebook. Students learn using the interactive eTextbook and Media Library with Active Figures that bring the material to life, anytime and anywhere they choose.
Not Available
LANGUAGES
English

Curriculum Details

1st Edition
Total Recommended Hours
Competencies & Objectives Lists
Levels 1-4: 835, includes 97.5 hours of Intro to Power Industry and Core hours Click here
Tools of the Trade
5 Hours

Module ID 32102-07; from Industrial Maintenance Mechanic Level One: Introduces hand and power tools used in industrial maintenance. Covers safety procedures and proper use of these tools.

Fasteners and Anchors
5 Hours

Module ID 32103-07; from Industrial Maintenance Mechanic Level One: Covers the hardware and systems used in industrial maintenance. Describes anchors and supports, their applications, and how to install them safely.

Oxyfuel Cutting
17.5 Hours

Module ID 32104-07; from Industrial Maintenance Mechanic Level One: Explains the safety requirements for oxyfuel cutting. Identifies oxyfuel cutting equipment and provides instructions for setting up, lighting, and using the equipment. Explains how to perform straight line cutting, piercing, beveling, washing, and gouging.

Gaskets and Packing
10 Hours

Module ID 32105-07; from Industrial Maintenance Mechanic Level One: Introduces gaskets and gasket material, packing and packing material, and types of O-ring material. Explains the use of gaskets, packing, and O-rings, and how to fabricate a gasket.

Craft-Related Mathematics
15 Hours

Module ID 32106-07; from Industrial Maintenance Mechanic Level One: Explains how to use ratios and proportions, solve basic algebra, area, volume, and circumference problems, and solve for right triangles using the Pythagorean theorem.

Construction Drawings
12.5 Hours

Module ID 32107-07; from Industrial Maintenance Mechanic Level One: Introduces plot plans, structural drawings, elevation drawings, as-built drawings, equipment arrangement drawings, P&IDs, isometric drawings, basic circuit diagrams, and detail sheets.

Pumps and Drivers
5 Hours

Module ID 32108-07; from Industrial Maintenance Mechanic Level One: Explains centrifugal, rotary, reciprocating, metering, and vacuum pump operation and installation methods, as well as types of drivers. Describes net positive suction head and cavitation.

Valves
5 Hours

Module ID 32109-07; from Industrial Maintenance Mechanic Level One: Identifies different types of valves and describes their installation as well as valve storage and handling.

Introduction to Test Instruments
7.5 Hours

Module ID 32110-07; from Industrial Maintenance Mechanic Level One: Introduces test equipment for industrial maintenance, including tachometers, pyrometers, strobe meters, voltage testers, and automated diagnostic tools.

Material Handling and Hand Rigging
15 Hours

Module ID 32111-07; from Industrial Maintenance Mechanic Level One: Introduces the equipment and techniques of material handling, and describes the procedures for rigging and communicating with riggers.

Mobile and Support Equipment
10 Hours

Module ID 32112-07; from Industrial Maintenance Mechanic Level One: Introduces the safety procedures and methods of operation for motorized support equipment, including forklifts, personnel lifts, compressors, and generators.

Lubrication
12.5 Hours

Module ID 32113-07; from Industrial Maintenance Mechanic Level One: Explains lubrication safety, storage, and classifications. Also explains selecting lubricants, additives, lubrication equipment, and lubricating charts.Explains lubrication safety, storage, and classifications. Also explains selecting lubricants, additives, lubrication equipment, and lubricating charts.

SMAW Equipment and Setup
5 Hours

Module ID 29107-09; from Welding Level One, Fourth Edition: Describes SMAW welding and welding safety. Explains how to connect welding current and set up arc welding equipment. Also explains how to use tools for cleaning welds.

Installing Mechanical Seals
20 Hours

Module ID 32308-08; from Industrial Maintenance Mechanic Level Three: Covers the function and advantages of mechanical seals, identifies parts and types of seals, and includes procedures for removing, inspecting and installing mechanical seals.

Conventional Alignment
30 Hours

Module ID 32306-08; from Industrial Maintenance Mechanic Level Three: Covers types of misalignment, aligning couplings using a straightedge and feeler gauge, adjusting parallel and angular alignment, using a dial indicator, and eliminating coupling stress.

Reverse Alignment
30 Hours

Module ID 32404-09; from Industrial Maintenance Mechanic Level Four: Describes preparation for dial indicator reverse alignment, and explains the procedures for setting up reverse alignment jigs. Explains graphic and mathematical techniques for aligning equipment based on reverse dial indicator measurements.

Basic Layout
20 Hours

Module ID 32201-07; from Industrial Maintenance Mechanic Level Two: Discusses the tools used in layout. Explains how to lay out baselines using the arc method and 3-4-5 method.

Advanced Trade Math
30 Hours

Module ID 32301-08; from Industrial Maintenance Mechanic Level Three: Explains right triangle trigonometry and its use in the trade. Also covers interpolation, equilateral and isosceles triangles and the laws of acute triangles.

Precision Measuring Tools
20 Hours

Module ID 32302-08; from Industrial Maintenance Mechanic Level Three: Explains how to select, inspect, use and care for levels, feeler gauges, calipers, micrometers, height gauges and surface plates, dial indicators, protractors, parallels and gauge blocks, trammels, and pyrometers.

Laser Alignment
25 Hours

Module ID 32405-09; from Industrial Maintenance Mechanic Level Four: Using one example system, describes the principles of using laser alignment systems to perform alignments.

Installing Belt and Chain Drives
10 Hours

Module ID 32307-08; from Industrial Maintenance Mechanic Level Three: Covers the sizes, uses, and installation procedures of six types of drive belts and two types of chain drives.

Introduction to Piping Components
5 Hours

Module ID 32202-07; from Industrial Maintenance Mechanic Level Two: Introduces chemical, compressed air, fuel oil, steam, and water systems. Explains how to identify piping systems according to color codes.

Introduction to Bearings
15 Hours

Module ID 32207-07; from Industrial Maintenance Mechanic Level Two: Introduces plain, ball, roller, thrust, guide, flanged, pillow block, and takeup bearings. Discusses bearing materials and designations.

Installing Bearings
20 Hours

Module ID 32303-08; from Industrial Maintenance Mechanic Level Three: Explains how to remove, troubleshoot, and install tapered, thrust, spherical roller, pillow block, and angular contact ball bearings.

Installing Couplings
15 Hours

Module ID 32304-08; from Industrial Maintenance Mechanic Level Three: Identifies various types of couplings, and covers installation procedures using the press-fit method and the interference-fit method. Also covers coupling removal procedures.

Copper and Plastic Piping Practices
5 Hours

Module ID 32203-07; from Industrial Maintenance Mechanic Level Two: Covers the selection, preparation, joining, and support of copper and plastic piping and fittings.

Introduction to Ferrous Metal Piping Practices
5 Hours

Module ID 32204-07; from Industrial Maintenance Mechanic Level Two: Covers iron and steel pipe and fittings and provides step-by- step instructions for cutting, threading, and joining ferrous piping.

Identify, Install and Maintain Valves
10 Hours

Module ID 32205-07; from Industrial Maintenance Mechanic Level Two: Explains how to remove and install threaded and flanged valves, how to replace valve stem O-ring and bonnet gaskets, and how to repack a valve stuffing box. Also discusses the purpose of valve packing.

Low-Pressure Steam Systems
10 Hours

Module ID 32208-07; from Industrial Maintenance Mechanic Level Two: Introduces the components and functions of basic steam systems, including boilers, steam traps, and blowdown recovery systems.

High-Pressure Steam Systems and Auxiliaries
20 Hours

Module ID 32209-07; from Industrial Maintenance Mechanic Level Two: Explains the functioning of high-pressure steam systems used in industry.

Heaters, Furnaces, Heat Exchangers, Cooling Towers, Fin Fans
30 Hours

Module ID 32211-07; from Industrial Maintenance Mechanic Level Two: Introduces equipment used to transfer and remove heat from systems in process.

Hydrostatic and Pneumatic Testing
10 Hours

Module ID 32206-07; from Industrial Maintenance Mechanic Level Two: Describes non-destructive and pressure testing of systems and equipment.

Installing Fans and Blowers
10 Hours

Module ID 15312-08; from Millwright Level Three: Explains how to install axial-flow fans, centrifugal fans, and roots-type and screw- type blowers.

Conveyors
5 Hours

Module ID 15401-08; from Millwright Level Four: Describes conveyor systems and their principles of operation.

Troubleshooting and Repairing Conveyors
12.5 Hours

Module ID 15402-08; from Millwright Level Four: Describes maintaining and repairing belt, roller, chain, screw, and pneumatic conveyors.

Basic Hydraulic Systems
10 Hours

Module ID 15409-08; from Millwright Level Four: Describes principles and types of hydraulic equipment and related safety procedures. Describes applications of hydraulic equipment.

Troubleshooting and Repairing Hydraulic Equipment
7.5 Hours

Module ID 15410-08; from Millwright Level Four: Explains inspecting hydraulic systems, diagnosing problems, and repairing these systems. Shows how to read hydraulic schematic symbols.

Motor-Operated Valves
15 Hours

Module ID 40313-09; from Industrial Maintenance E&I Technician Level Three: Covers motor-driven valves, ranging from small, servo- mechanical actuators to large valves that could only be operated by several people if they were not motor driven. Includes electrical, pneumatic, and hydraulic operators.

Advanced Blueprint Reading
25 Hours

Module ID 32402-09; from Industrial Maintenance Mechanic Level Four: Describes the use of drawing sets to obtain system information. Explains the process of identifying a part of a machine for repair or replacement from a set of drawings.

Vibration and Balancing
12.5 Hours

Module ID 52401-10: Reviews machine basics and explains the causes of machine vibrations. Reviews the basics of vibration analysis and covers the devices used to detect and analyze vibration signatures. Explains how and why vibration analysis is used as part of predictive maintenance programs. Describes field machine balancing.

Preventive and Predictive Maintenance
10 Hours

Module ID 32401-09; from Industrial Maintenance Mechanic Level Four: Explains preventive and predictive maintenance and non-destructive testing, and introduces the basic techniques for testing. Also describes lubricant analysis, and acoustic, infrared, and vibration testing.

Fuel Preparation and Delivery Equipment
25 Hours

Module ID 52402-10: Explains the basic operations of a coal-fired boiler system. Describes the delivery processes from the storage yard into the coal preparation equipment, and from the equipment into the furnace. Addresses the maintenance checks that need to be made on coal delivery and preparation equipment and explains how solid fuel wastes are disposed of in coal-burning furnace systems. Describes how other solid-fuel furnaces, such as biomass furnaces, are used with boilers.

Introduction to Tube Work
10 Hours

Module ID 32212-07; from Industrial Maintenance Mechanic Level Two: Covers the basics of working with heat exchanger and furnace tubing and tube sheets.

Compressors and Pneumatic Systems
35 Hours

Module ID 32403-09; from Industrial Maintenance Mechanic Level Four: Describes the theory and practice of compressing and transporting gases. Explains the types and principles of compressors and compressed air treatment equipment, as well as compressed air use and safety.

Troubleshooting and Repairing Pumps
10 Hours

Module ID 32407-09; from Industrial Maintenance Mechanic Level Four: Explains how to inspect, troubleshoot, disassemble, assemble, and install a pump. Also describes the process of preparing for startup.

Troubleshooting and Repairing Gearboxes
20 Hours

Module ID 32408-09; from Industrial Maintenance Mechanic Level Four: Describes types and operation of gearboxes, and gearbox diagnostics. Explains how to troubleshoot, remove, and disassemble gearboxes, how to identify gear wear patterns, and how to install and maintain gearboxes.

Setting Baseplates and Prealignment
30 Hours

Module ID 32305-08; from Industrial Maintenance Mechanic Level Three: Explains how to lay out and install baseplates and soleplates. Describes how to field-verify a plate installation. Covers precision leveling procedures and performing clearance installation. Also describes basic steps for setting motors and pumps.

Turbines
20 Hours

Module ID 15505-09; from Millwright Level Five: Describes types of turbines and their components. Describes the operation and common applications of particular types, including gas, steam, and water turbines.

Maintaining and Repairing Turbine Components
15 Hours

Module ID 15506-09; from Millwright Level Five: Describes the process of inspecting and repairing key components of turbines. Explains the guidelines for maintaining large steam turbines.

Instructor Resources

Instructor Toolbox

NCCER’s Instructor Toolbox provides easy access to important instructional resources for your training program. You’ll find downloadable course planning tools, examples of classroom activities and projects, and instructor tips and best practices to help you enhance your program.

Instructor Requirements

In addition to our standard instructor requirements, instructors of this craft must achieve:

  • NCCER certification as an instructor in a related discipline, including: Millwright, Industrial Maintenance Mechanic, Industrial Maintenance E&I, and/or

  • Experience working in a power plant or power-generation facility (Qualified Journey-level Power Plant Maintenance Mechanic/Electrician/I&C Tech)

Assessments

NCCER’s assessments evaluate the knowledge of an individual in a specific craft area and provide a prescription for upgrade training when needed. All assessments are based upon the NCCER Curriculum and have been developed in conjunction with subject matter experts from the industry. Click the assessment title below to open its specifications.

Power Generation Maintenance Mechanic