Red Seal Millwright study plan

Apply lockout/tagout, PPE and machine-guarding requirements to three described maintenance scenarios and state the hazard controls for each.

Compute driver/driven speed, torque and power for belt, chain, gear and compound gear trains, including idler and multi-stage arrangements.

Measure shaft diameter and bore with a micrometer and dial bore gauge and record readings to 0.01 mm.

Read a mechanical assembly drawing: extract part numbers, fits and tolerances, and torque values from the title block and bill of materials.

Match belt, chain and gear failure patterns (glazing, elongation, spalling, pitting, tooth fracture, fretting) to their root causes.

Set correct belt tension, sheave alignment and chain sag using straight-edge and tension-gauge methods.

Describe backlash, contact-pattern and lubrication checks performed after installing a spur or helical gearbox.

Compare rigid, elastomeric, grid and gear couplings and select one for a stated torque and misalignment duty.

Classify bearing types by load direction and application, and state correct mounting and removal methods (press, induction heater, hydraulic nut).

Explain internal clearance, preload and interference fits, and derive a shaft fit from a tolerance table.

Select lubricant viscosity and grade for a stated speed, temperature and load, and describe grease versus oil application methods.

Distinguish lip, labyrinth, mechanical and packing seal types and name the cause of leakage for described failures.

Trace a centrifugal pump curve: calculate head, flow and NPSH available, and identify the symptoms of cavitation.

Sequence a pump-to-motor alignment and compare rim-and-face, reverse-dial and laser alignment methods.

Identify hydraulic system components from symbols and follow pressure and flow troubleshooting steps on a described circuit.

Apply hazard communication and permit-to-work practice to a pump overhaul job plan.

Calculate load weight, centre of gravity and sling-leg tension for two-, three- and four-leg lifts.

Select and inspect slings, shackles and rigging hardware against rated capacity and state rejection criteria.

Plan a lift end to end: rigging sketch, hitch type, tag lines and identified hazards.

Identify conveyor components (belt, idlers, pulleys, take-up, drive) and explain belt tracking and tensioning adjustments.

Explain conveyor safety devices and guarding, belt splicing methods and take-up adjustment limits.

Build a preventive maintenance schedule from manufacturer intervals for a drive, a pump and a conveyor.

Interpret vibration, thermography, oil analysis and ultrasound readings to classify a developing fault.

State alarm and trend limits for bearings, alignment and lubrication condition monitoring.

Apply a structured troubleshooting sequence (gather data, isolate, verify, correct, confirm) to three described equipment faults.

Explain the installation sequence: foundation, baseplate grouting, soft-foot correction, pipe-strain relief, alignment and run-in.

Perform soft-foot and shaft-alignment calculations to correct angular and parallel misalignment with shim and move values.

Describe commissioning records: checklists, rotation checks, no-load run and handover documentation.

Re-test the weakest two domains with timed practice sets and log every missed item with its correction.

Reproduce key formulas from memory: sling tension, drive ratio, pump head, shim/move alignment values.

Complete a full-length timed mock exam under exam conditions.

Review documentation and communication tasks: work orders, service reports and code references.