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Mechanical Power 2

Course Number: MEC 122
Transcript Title: Mechanical Power 2
Created: May 12, 2014
Updated: May 12, 2014
Total Credits: 5
Lecture Hours: 40
Lecture / Lab Hours: 0
Lab Hours: 30
Satisfies Cultural Literacy requirement: No
Satisfies General Education requirement: No
Grading options: A-F (default), P-NP, audit

Prerequisites

WR 115, RD 115, MTH 20 or equivalent placement test scores
MEC 121

Course Description

Introduces the process of power generation. Covers construction techniques involving cranes, rigging, and mechanical alignment procedures. Includes the disassembly and assembly of a functioning power generating turbine and participation in a safety workshop at a local wind farm. Prerequisites: WR 115, RD 115 and MTH 20 or equivalent placement test scores; MEC 121. Audit available.

Intended Outcomes

Upon successful completion of this course, students will be able to:

  1. Understand the mechanical process of power generation.
  2. Apply safety processes and procedures around cranes and other heavy machinery.
  3. Use alignment techniques.
  4. Apply principles of rigging and rigging safety when using standard lifting hardware.
  5. Assemble and disassemble a commercial wind turbine as part of a team.
  6. Use hand and power tools safely and appropriately.

Outcome Assessment Strategies

Assessment methods are to be determined by the instructor.  Typically, in class exams and quizzes, and homework assignments will be used.  Lab work is typically assessed by a lab notebook, formal lab reports, performance of experiments, and possibly a lab exam.

Course Activities and Design

Lecture and discussion are the instructional methods used. Weekly homework is assigned.  Laboratory activity includes disassembly, diagnosis, and assembly of mechanical equipment, making measurements using mechanical trades’ equipment.  Review and discussion of results.

The focus of this term is:  Rigging and rigging safety, mechanical alignment, crane safety, couplings, run-out correction, and related subjects.

Course Content (Themes, Concepts, Issues and Skills)

  1. Disassemble and assemble a functioning wind turbine.
  2. Principles and logistics of cranes, rigging, slings, and other lifting apparatus.
  3. Principles of crane and rigging safety.
  4. Mechanical and laser alignment.
  5. Basic maintenance and operation of a wind turbine including nacelle, gearbox and bearing, tower, pitch, yaw, and control.
    • How to assemble a scale model of a functioning wind turbine.
  6. Principles and logistics of cranes and rigging.
    • Center of gravity of crane-load systems.
    • Lever principles as applied to crane and load:
      • Tipping axis.
      • Fulcrum.
      • Load.
    • Wind loading.
    • Blocking, outriggers.
    • Maintaining clearance of power lines.
    • Rigging:
      • Converting between US Standard Weight System to metric weight system.
      • Slings:
        • Load edge related to sling.
        • Types and characteristics.
        • Hardware and correct use of lifting capacity.
    • Eyebolts and hoist rings.
      • Sling inspections and safe handling.
        • Types of hitches and lifting capacities.
        • Wire rope, synthetic web, and round slings.
        • Removal-from-service issues:
          • Inspection and removal.
          • Capacity loss.
          • Crane safety.
          • Mechanical alignment:
    • Pipes with flange alignment.
    • Shaft-to-shaft alignment procedures.
    • Centerline alignment.
    • Two 3” pipes with flange alignment.
    • Types of misalignment.
    • Two-plane alignment.
    • Run-out correction.
    • Preparation of driver and driver unit.
    • Alignment operations.
    • Coupling types.
    • Bearings — types, float, installation best practices.
    • Calculating for alignment.
    • Alignment specifications and tolerance.
    • Tools:
      • Straight edge, feeler gauge (single/double), taper gauge (gap gauge), Cliter spark plug gauge taper.
    • Measurement of alignment.
    • Surface alignment method.
    • Tools for alignment:
      • Porta power, jacks, etc.
      • Laser alignment.
  7. Basic maintenance and operation of a wind turbine.
  8. Basic mechanical theory as applied to gear ratios and gearboxes.
  9. Application of mechanical theory as applied to levers, wheels, axles, pulleys, and other mechanisms to wind turbine construction.
  10. Propeller blade pitch — hydraulic/motor type.
  11. Propeller blade yaw — nacelle rotation, motor type and actuator.
  12. Drive trains, drive lines, U joints, and transmission.
  13. Towers.
  14. Introduction to tools of the trade:
    • Wrenches, torque wrenches, hammers, screwdrivers, grease guns, DMM, porta power, other miscellaneous tools, and dirty grease disposal.
  15. Airframe aerodynamics (wind – surface boundary effects on propellers, air foils, and rotors).
  16. 3-Phase power line connections.
  17. Substations.
  18. Generator-Power line setups (no substation).
  19. How to read and analyze topographic maps.
  20. Identifying ravines, mountain ridges, gullies, cliffs, flatlands, and bodies of water.
  21. How to read and analyze wind maps.
  22. How to make reasonable decisions concerning wind farm development on promising areas of land, including citing concerns if and when necessary.
  23. How to make short-term weather forecasts with the goal of maintaining worker and equipment safety if bad weather approaches (such as electrical and thunderstorms, squall lines, high winds, etc.).
  24. How to make reports and other word-processed documents using MS Word.
  25. How to create and manipulate spreadsheets using MS Excel.
  26. How to create, maintain, and manipulate relational databases using MS Access.
  27. Techniques used in and logistics of cranes and rigging in wind turbine construction.
  28. Non-destructive materials testing:
    • Ultrasound and scanning electron microscope (SEM):
      • Theory of operation:
  29. SEM
    • Magnetic focusing of electron beam.
    • Secondary electron imaging.
    • Back-scattered electron imaging.
  30. Sound beam:
    • Convergent.
    • Near-field.
    • Far-field.
    • Divergence angle.
    • Acoustic axis.
  31. Testing methods.
    • Identification of reflectors, discontinuities, and other imperfections and impurities.
    • Pulse echo method:
      • Speed of sound in materials.
      • Longitudinal acoustical waves.
      • Oscilloscope display: initial and reflected pulse.
      • Using the intermediate echo to detect flaws.
  32. Location of discontinuity.
  33. Near, far, and dead zones.
    • Types of probes:
      • Transverse/shear waves.
      • Angle beam probes: angle of incidence, angle of reflection, refraction, sound velocity, and critical angles.
    • Problem-solving methods.
    • Failure analysis.
    • DGS and DAC methods.
    • Document test results.
    • Overview of data interpretation (diagnosis).
  34. Fiber optic and cat-5 networking.
  35. Sensors.

Topic Addenda:

  • Haz-Mat handling, storage, and use.
  • Site environmental, wildlife, and cultural issues.
  • Vehicle safety and maintenance.
  • Site safety.
  • Fall protection.
  • Road maintenance.
  • Weed control.
  • CMMS — maintenance management.
  • Preventive and predictive maintenance.